US4179427A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Phenolic resin-polyisocyanate binders
Assignee: Ashland Inc
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Filing: 1978-03-21
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Granted: 1979-12-18
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Expires: 1998-03-21
Abstract
Abstract Phenolic resin-polyisocyanate binder systems comprising aqueous emulsions of a phenolic resin and a liquid polyisocyanate and a tertiary amine or metal ion curing agent can be made and used free of organic solvents, thereby providing improved environmental conditions. These binders are useful as foundry core and mold binders in both cold box and no bake operations.
Inventors
- 👤 John J. Gardikes
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 02:30
CPC Classifications
C; C08; C08G; C08G18/00; C08G18/06; C08G18/28; C08G18/40; C08G18/54; C08G18/542; B; B22; B22C; B22C1/00; B22C1/16; B22C1/20; B22C1/22; B22C1/2233; B22C1/2273; C08G8/00; C08G8/04; C08G8/08; C08G8/10
Claims Analysis
Total Claims: 21
Claim 1
Independent Claim
101 words
A binder composition comprising in admixture a resin component, a hardener component and a curing agent, wherein the resin component comprises an aqueous emulsion of a phenolic resin which comprises the condensation product of a phenol having the general formula: ##STR4## wherein A, B and C are hydrogen, hydrocarbon radicals, oxyhydrocarbon radicals or halogen, with an aldehyde having the general formula R'CHO wherein R' is hydrogen or a hydrocarbon radical of 1 to 8 carbon atoms; the hardener component comprising a liquid polyisocyanate containing at least two isocyanate groups; and the curing agent comprising a tertiary amine or a metal ion.
Claim 2
Dependent Claim
101 words
A binder composition comprising in admixture a resin component, a hardener component and a curing agent, wherein the resin component comprises an aqueous emulsion of a phenolic resin which comprises the condensation product of a phenol having the general formula: ##STR4## wherein A, B and C are hydrogen, hydrocarbon radicals, oxyhydrocarbon radicals or halogen, with an aldehyde having the general formula R'CHO wherein R' is hydrogen or a hydrocarbon radical of 1 to 8 carbon atoms; the hardener component comprising a liquid polyisocyanate containing at least two isocyanate groups; and the curing agent comprising a tertiary amine or a metal ion.
Claim 3
Dependent Claim
52 words
A binder composition according to claim 1 wherein the phenolic resin is a benzylic ether resin containing a unit of the formula ##STR5## wherein A, B and C are hydrogen, hydrocarbon radicals, oxyhydrocarbon radicals, or halogen and wherein R is a hydrogen or a hydrocarbon radical of 1 to 8 carbon atoms.
Claim 4
Dependent Claim
69 words
A binder composition according to claim 1 wherein the phenolic resin is benzylic ether resin having the formula ##STR6## wherein R is hydrogen or a phenolic substituent, the sum of m and n is at least two, the ratio of m to n is at least one, X is hydrogen or methylol end group and the ratio of methylol end groups to hydrogen end groups is at least one.
Claim 5
Dependent Claim
29 words
A binder composition according to claim 1, claim 2, or claim 3 wherein the aqueous emulsion of phenolic resin comprises from about 35% to about 75% by weight resin.
Claim 6
Dependent Claim
30 words
A binder composition according to claim 1, claim 2, or claim 3 wherein the aqueous emulsion of a phenolic resin comprises from about 45% to about 65% by weight resin.
Claim 7
Dependent Claim
30 words
A binder composition according to claim 1, claim 2 or claim 3 wherein the aqueous emulsion of a phenolic resin comprises from about 50% to about 60% by weight resin.
Claim 8
Dependent Claim
36 words
A method of binding materials together which comprises applying to the material a binding amount of the binder composition of claim 1, shaping the material into the desired shape and allowing the binder composition to cure.
Claim 9
Dependent Claim
20 words
A method according to claim 7 wherein the curing agent is mixed with the resin component or the hardener component.
Claim 10
Dependent Claim
40 words
A method according to claim 7 wherein the resin component and hardener component are applied to the material, the material shaped into the desired shape, and the shaped material contacted with a tertiary amine to effect curing of the binder.
Claim 11
Dependent Claim
16 words
A method according to claim 8 wherein the tertiary amine is in vapor or gaseous form.
Claim 12
Dependent Claim
24 words
A foundry mix containing sand as the major constituent and a binding amount of the binder of claim 1, claim 2 or claim 3.
Claim 13
Dependent Claim
65 words
A method of preparing shaped foundry cores or molds which comprises: (a) forming a foundry mix by uniformly distributing on a foundry aggregate containing sand as the major constituent a binding amount of the resin component, hardener component and curing agent of claim 1; (b) shaping the foundry mix in a pattern; and (c) allowing the binder composition in the shaped foundry mix to cure.
Claim 14
Dependent Claim
13 words
The method of claim 12 wherein the curing agent is a tertiary amine.
Claim 15
Dependent Claim
12 words
The method of claim 13 wherein the curing agent is 4-phenylpropyl pyridine.
Claim 16
Dependent Claim
68 words
A method of preparing shaped foundry cores or molds which comprises: (a) forming a foundry mix by uniformly distributing on a foundry aggregate containing sand as the major constituent a binding amount of the resin component and the hardener component of claim 1; (b) shaping the foundry mix in a pattern; and (c) contacting the shaped foundry mix with a tertiary amine to effect curing of the binder.
Claim 17
Dependent Claim
15 words
The method of claim 15 wherein the tertiary amine is in vapor or gaseous form.
Claim 18
Dependent Claim
16 words
The method of claim 16 wherein the tertiary amine is passed through the shaped foundry mix.
Claim 19
Dependent Claim
24 words
The method of claim 16 wherein the tertiary amine is suspended in an inert gas stream which is passed through the shaped foundry mix.
Claim 20
Dependent Claim
12 words
The method of claim 18 wherein the tertiary amine is triethyl amine.
Claim 21
Dependent Claim
12 words
The method of claim 18 wherein the tertiary amine is dimethylethyl amine.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1982-12-17 | 1983-06-18 | 1983-12-18 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1986-12-17 | 1987-06-18 | 1987-12-18 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1990-12-17 | 1991-06-18 | 1991-12-18 | $7700.00 | Window Closed / Lapsed |