US4711669A — Method of manufacturing a bonded particulate arti…

Claim 1

Independent Claim 91 words

A method of manufacturing a bonded particulate article comprising the steps of (i) admixing particulate material with a binder system, the binder system being formed by admixing a polyol comprising a hydrolyzed, gelatinized amylaceous material, a crosslinker for said polyol (ii) comprising the reaction product of gloxal, urea and formaldehyde, alone, or in further combination with ethylene glycol, a solvent, and an acid wherein said reaction is carried out at a pH of below about 7; (ii) forming the admixture into a shape; and (iii) curing to produce the bonded article.

Claim 2

Independent Claim 91 words

A method of manufacturing a bonded particulate article comprising the steps of (i) admixing particulate material with a binder system, the binder system being formed by admixing a polyol comprising a hydrolyzed, gelatinized amylaceous material, a crosslinker for said polyol (ii) comprising the reaction product of gloxal, urea and formaldehyde, alone, or in further combination with ethylene glycol, a solvent, and an acid wherein said reaction is carried out at a pH of below about 7; (ii) forming the admixture into a shape; and (iii) curing to produce the bonded article.

Claim 3

Dependent Claim 36 words

A method as defined in claim 1 wherein step (ii) is carried out in a heated mold, and step (iii) is carried out by removing the article from the heated mold and allowing it to cool.

Claim 4

Dependent Claim 23 words

A method as defined in claim 1 wherein said crosslinker is a compound of the formula ##STR5## or a mixture of such compounds.

Claim 5

Dependent Claim 12 words

A method as defined in claim 1 wherein the solvent is water.

Claim 6

Independent Claim 76 words

A method of manufacturing a bonded particulate article comprising the steps of (i) admixing sand with a binder system, the binder system being formed by admixing a polyol comprising a hydrolyzed, gelatinized amylaceous material, a crosslinker for said polyol (ii) comprising the reaction product of glyoxal, urea and formaldehyde, alone or in further combination with ethylene glycol, water, and an acid; (ii) forming the admixture into a shape; and (iii) curing to produce the bonded article.

Claim 7

Independent Claim 76 words

A method of manufacturing a bonded particulate article comprising the steps of (i) admixing sand with a binder system, the binder system being formed by admixing a polyol comprising a hydrolyzed, gelatinized amylaceous material, a crosslinker for said polyol (ii) comprising the reaction product of glyoxal, urea and formaldehyde, alone or in further combination with ethylene glycol, water, and an acid; (ii) forming the admixture into a shape; and (iii) curing to produce the bonded article.

Claim 8

Independent Claim 72 words

A method of manufacturing a bonded particulate article comprising the steps of (i) admixing sand with a binder system wherein the latter is formed by admixing a hydrolyzed, gelatinized amylaceous saccharide-containing material with a crosslinker for said saccharide containing material comprising the reaction product of glyoxal, urea and formaldehyde, alone, or in combination with ethylene glycol, water, and an acid; (ii) forming the article in a mold; and (iii) desolventizing the article.

Claim 9

Independent Claim 72 words

A method of manufacturing a bonded particulate article comprising the steps of (i) admixing sand with a binder system wherein the latter is formed by admixing a hydrolyzed, gelatinized amylaceous saccharide-containing material with a crosslinker for said saccharide containing material comprising the reaction product of glyoxal, urea and formaldehyde, alone, or in combination with ethylene glycol, water, and an acid; (ii) forming the article in a mold; and (iii) desolventizing the article.

Claim 10

Dependent Claim 17 words

A method as defined in claim 6 wherein the desolventing is accomplished by the application of heat.

Claim 11

Dependent Claim 23 words

A method as defined in claim 6 wherein the application of heat is accomplished at least in part by use of microwave energy.

Claim 12

Dependent Claim 23 words

A method as defined in claim 6 wherein said crosslinker is a compound of the formula ##STR6## or a mixture of such compounds.

Claim 13

Dependent Claim 49 words

A bonded particulate article manufactured by the method of claim 6 comprising, before desolventizing, 80%-99% of particulate material and 1%-20% of binder system, with the latter being comprising of 20%-50% of hydrolyzed, gelatinized amylaceous material, 3%-60% of crosslinker, and 0.2%-10% of an acid, and 15-85% of solvent, by weight.

Claim 14

Dependent Claim 14 words

An article as defined in claim 10 wherein the article is a foundary core.

Claim 15

Independent Claim 117 words

A method of manufacturing a formed article comprising: (a) dispersing fillers, extenders and pigments in a hydrolyzed, gelatinized amylaceous material in an amount up to 80% and adding water to the mixture; (b) adding a mixture of a heterocyclic crosslinking compound of the formulae ##STR7## or a mixture of such compounds, and water wherein said compound or compounds are the reaction products of a reaction carried out at a pH of below about 7; (c) controlling the rate of the crosslinking reaction between the hydrolyzed, gelatinized amylaceous material and said heterocyclic compound by the use of an acid; (d) forming the mixture into a shape; and (e) causing the mixture to cure by the application of heat.

Claim 16

Independent Claim 117 words

A method of manufacturing a formed article comprising: (a) dispersing fillers, extenders and pigments in a hydrolyzed, gelatinized amylaceous material in an amount up to 80% and adding water to the mixture; (b) adding a mixture of a heterocyclic crosslinking compound of the formulae ##STR7## or a mixture of such compounds, and water wherein said compound or compounds are the reaction products of a reaction carried out at a pH of below about 7; (c) controlling the rate of the crosslinking reaction between the hydrolyzed, gelatinized amylaceous material and said heterocyclic compound by the use of an acid; (d) forming the mixture into a shape; and (e) causing the mixture to cure by the application of heat.

Claim 17

Dependent Claim 35 words

A method as defined in claim 12 wherein the mixture used in steps (a), (b) and (c) is within the limits of 15-85% water, 20-55% amylaceous material, 3-60% heterocyclic compound, 0.2-10% acid and 15-85% water.

Claim 18

Independent Claim 122 words

A method of manufacturing a resinlike material suitable for formed articles with the binder produced by the following steps: (a) crosslinking a hydrolyzed, gelatinized material with a heterocyclic compound of the formula ##STR8## or a mixture of such compouns in water wherein said compound or compounds are the reaction products of a reaction carried out at a pH of below about 7; (b) controlling the rate of the crosslinking reaction between the hydrolyzed gelatinized amylaceous material and said heterocyclic compound by the use of an acid salt; and said method including the following steps; (c) dissolving or dispersing the acid, hydrolyzed, gelatizinzed amylacous material and said heterocyclic compound in water; and (d) causing the mixture to react by the application of heat.

Claim 19

Independent Claim 122 words

A method of manufacturing a resinlike material suitable for formed articles with the binder produced by the following steps: (a) crosslinking a hydrolyzed, gelatinized material with a heterocyclic compound of the formula ##STR8## or a mixture of such compouns in water wherein said compound or compounds are the reaction products of a reaction carried out at a pH of below about 7; (b) controlling the rate of the crosslinking reaction between the hydrolyzed gelatinized amylaceous material and said heterocyclic compound by the use of an acid salt; and said method including the following steps; (c) dissolving or dispersing the acid, hydrolyzed, gelatizinzed amylacous material and said heterocyclic compound in water; and (d) causing the mixture to react by the application of heat.

Claim 20

Dependent Claim 34 words

A method as defined in claim 14 wherein prior to the application of heat up to 80% the weight of the binder system of fillers, pigments and extenders are dispersed in the binder system.

Claim 21

Dependent Claim 40 words

A method as defined in claim 14 wherein up to 80% of the weight of the binder system of fillers, pigments and extenders are pre-mixed with the hydrolyzed, gelatinized amylaceous material and steps (a) and (b) are carried out simultaneously.

Claim 22

Independent Claim 65 words

A method of manufacturing a foundry core comprising mixing sand and heat-accelerated curable binder system wherein the binder system is produced by the following steps, the percentages being a percent of sand: (a) crosslinking about 1-3% of a hydrolyzed, gelatinized amylaceous material with about 0.1-3% of a crosslinker comprising a heterocyclic compound of the formula ##STR9## in about a 40 to 60% aqueous solution; and

Claim 23

Independent Claim 65 words

A method of manufacturing a foundry core comprising mixing sand and heat-accelerated curable binder system wherein the binder system is produced by the following steps, the percentages being a percent of sand: (a) crosslinking about 1-3% of a hydrolyzed, gelatinized amylaceous material with about 0.1-3% of a crosslinker comprising a heterocyclic compound of the formula ##STR9## in about a 40 to 60% aqueous solution; and

Claim 24

Dependent Claim 50 words

(b) controlling the rate of reaction by the use of 0.3-1.0% of an acid as a catalyst, said mixture also comprising 0-10% clay, 0-10% silica flour, 0-10% iron oxide, and an effective amount of a release agent selected from the group comprising wax, wax emulsion, asphalt emulsion, and wax-asphalt emulsion.

Claim 25

Dependent Claim 50 words

(b) controlling the rate of reaction by the use of 0.3-1.0% of an acid as a catalyst, said mixture also comprising 0-10% clay, 0-10% silica flour, 0-10% iron oxide, and an effective amount of a release agent selected from the group comprising wax, wax emulsion, asphalt emulsion, and wax-asphalt emulsion.

Claim 26

Dependent Claim 27 words

A method as defined in claim 17 including the step of curing the core for 5-180 seconds in a hot box at a temperature between 250°-550° F.

Claim 27

Dependent Claim 18 words

A method as defined in claim 18 followed by the step of postcuring the core by microwave energy.

Claim 28

Dependent Claim 141 words

A method as defined in claim 17 wherein the amylaceous material is the product of a process comprising the steps in the following sequence: (a) hydrolyzing a material selected from corn flour, corn meal, corn grits, corn starch, sorghum flour, sorghum meal, sorghum grits, wheat flour, wheat starch, or a mixture of any of the foregoing at moistures between 5 and 12% by weight of the humidified material using between 0.1 and 2% by weight acid; (b) adjusting the pH of the acid hydrolyzed amylaceous material to between 3 and 6 obtained on a 10% solids water slurry; (c) gelatinizing the pH adjusted acid hydrolyzed amylaceous material at moisture levels between 15 and 40% and at temperatures of between 212° F. and 400° F.; (d) removing water from the gelatinized product; and (e) comminuting the dried amylaceous mass to a flour.

Claim 29

Dependent Claim 36 words

A method as defined in claim 17 wherein the acid is selected from acetic acid, hydrochloric acid, sulfuric acid, a zinc salt, a magnesium salt, an aluminum salt or a mixture of any of the foregoing.

Claim 30

Dependent Claim 13 words

A method as defined in claim 21 wherein the acid is zinc nitrate.

Claim 31

Dependent Claim 13 words

A method as defined in claim 21 wherein the acid is magnesium nitrate.

Claim 32

Dependent Claim 22 words

A method as defined in claim 17 which includes the step of removing the core from the form and drying the core.

Claim 33

Dependent Claim 15 words

A method as defined in claim 24 wherein the drying is performed in an oven.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1990-12-07	1991-06-08	1991-12-08	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1994-12-07	1995-06-08	1995-12-08	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1998-12-07	1999-06-08	1999-12-08	$7700.00	Window Closed / Lapsed

Method of manufacturing a bonded particulate article by reacting a hydrolyzed amylaceous product and a heterocyclic compound

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