Ashland, Inc.

Thomas E Dando

Heimo J Langer

William R Dunnavant

Robert Bernard Fechter

Ken K Chang

Chia-hung Chen

David A Hutchings

Albert Leonard Haugse

A Leonard Haugse

Gary W Strehl

This invention relates to an organic foundry binder containing an alkyl resorcinol, or preferably a readily available mixture of alkyl resorcinols, and derivatives thereof. Preferably, the organic foundry binder is a furan binder. Foundry mixes are prepared by mixing the binder with a foundry aggregate. Foundry shapes (molds and cores) are prepared by shaping the mix and allowing it to cure to form a workable foundry shape. The invention also relates to the preparation of metal castings using the foundry shapes and the metal castings prepared with the foundry shapes.

Foundry binder systems containing an alkyl resorcinol and their use

This invention relates to a polyurethane no-bake foundry binder comprising (1) phenolic resin component which comprises (a) a phenolic resin, (b) hydrofluoric acid, and (c) a silane, and (2) an organic polyisocyanate component, and (3) a liquid tertiary amine catalyst component. The binders are used to prepare foundry mixes by mixing the binder with a foundry aggregate. Foundry shapes are prepared with the mixes by the no-bake process and are used to cast metal parts.

Polyurethane forming no-bake foundry binders

This invention relates to polyurethane-forming foundry binder systems and foundry mixes which comprise a foundry aggregate, said foundry binder system, and a liquid amine curing catalyst. The binder system comprises a polyol component containing a polyether polyol and a monomeric glycol, and an organic polyisocyanate component. The foundry mixes are used to prepare foundry shapes made from foundry mixes by a no-bake process.

No-bake foundry mixes and their uses

This invention relates to benzylic ether phenolic resole resins prepared in a sealed reaction vessel and their uses. The benzylic ether phenolic resole resins are prepared by heating phenol and an aldehyde in a sealed reaction vessel in the presence of a divalent metal catalyst without removing water generated by the reaction until an appropriate endpoint for the resin is reached. The benzylic ether phenolic resole resins produced by the process are preferably free or essentially free of unreacted formaldehyde and can be used in the resin component of phenolic-urethane foundry binders to make foundry cores and/or molds by the cold-box and no-bake processes. The cores and/or molds are used for making metal castings.

Benzylic ether phenolic resole resins and their uses

No-bake foundry mixes and their use

This invention relates to a process for preparing benzylic ether phenolic resole resins in a sealed reaction vessel. The benzylic ether phenolic resole resins are prepared by heating phenol and an aldehyde in a sealed reaction vessel in the presence of a divalent metal catalyst without removing water generated by the reaction until an appropriate endpoint for the resin is reached. The benzylic ether phenolic resole resins produced by the process are preferably free or essentially free of unreacted formaldehyde and can be used in the resin component of phenolic-urethane foundry binders to make foundry cores and/or molds by the cold-box and no-bake processes. The cores and/or molds are used for making metal castings.

Process for preparing benzylic ether phenolic resole resins

This invention relates to benzylic ether phenolic resole resins prepared in a sealed reaction vessel. The benzylic ether phenolic resole resins are prepared by heating phenol and an aldehyde in a sealed reaction vessel in the presence of a divalent metal catalyst without removing water generated by the reaction until an appropriate endpoint for the resin is reached. The benzylic ether phenolic resole resins produced by the process are preferably free or essentially free of unreacted formaldehyde and can be used in the resin component of phenolic-urethane foundry binders to make foundry cores and/or molds by the cold-box and no-bake processes. The cores and/or molds are used for making metal castings.

Benzylic ether phenolic resole resins

This invention relates to a heat cured foundry binder system comprising as separate components (A) a furan resin, and (B) an effective amount of a curing catalyst composition comprising water, a copper aryl sulfonate, a aryl sulfonic acid, preferably polyvinyl alcohol, and a copper halide.

Heat cured foundry binder systems and their uses

This invention relates to a hot-box foundry mix. The hot-box foundry mix comprises (a) an aggregate (b) a thermosetting resin; (c) a latent acid curing catalyst; and (d) an effective benchlife extending amount of a compound selected from the group consisting of an alkaline earth metal carbonate, an alkaline earth metal oxide, and mixtures thereof. The hot-box foundry mixes are used to prepare foundry molds and cores. The foundry molds and cores are used to cast metals.

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Sunbury, OH, United States of America

Thomas E Dando