Claims
- 1. A method of making a foundry mould shape or core shape comprising:
- (1) preparing a composition;
- (2) forming the product of step (1) into a shape; and
- (3) allowing said shape to harden
- wherein said composition comprises a mixture of:
- (a) a granular refractory material;
- (b) from 0.25% to 8% by weight based on the weight of the granular refractory material of an aqueous solution having a solids content of 25% to 75% by weight of an alkali phenolformaldehyde resole resin having a formaldehyde:phenol molar ratio in the range of from 1.2:1 to 2.6:1 and an alkali:phenol molar ratio in the range of from 0.2:1 to 1.2:1, said aqueous solution of resole resin having a viscosity in the range of from 20 cP to 1000 cP at 25.degree. C.;
- (c) a carbonifiable material capable of evolving at least 20% based on its original weight of lustrous carbon, as measured by the Bindernagel test;
- (d) an amount effect to catalyze the curing of the resin of at least one liquid organic ester; and
- wherein said carbonifiable material comprises styrenated phenol.
- 2. A method of making a foundry mould or core shape comprising:
- (1) forming a mixture of
- (a) granular refractory material;
- (b) aqueous solution of alkali phenolformaldehyde resole resin; and
- (c) carbonifiable material capable of evolving 20% lustrous carbon based on its original weight of lustrous carbon as measured by the Bindernagel test,
- wherein said carbonifiable material comprises styrenated phenol;
- wherein the amount of said aqueous solution of resole resin is 0.25% to 8% by weight based on the weight of said granular refractory material;
- wherein said aqueous solution of resole resin has a solids content of 25% to 75% by weight;
- wherein said resole resin has a formaldehyde to phenol molar ratio in the range of from about 1.2:1 to about 2.6:1;
- wherein said aqueous solution of resole resin has an alkali to phenol molar ratio in the range of from 0.2:1 to about 1.2:1;
- and wherein said aqueous resole solution has a viscosity in the range of from about 20 cP to about 1000 cP at 25.degree. C.;
- (2) forming the product of step (1) into a desired shape; and
- (3) gassing the formed mixture in said shape with a curing agent selected from the group consisting of methyl formate, ethyl formate, propyl formate, isopropyl formate, and mixtures thereof, to cure said resin.
- 3. The method of claim 2 wherein said alkali resole is selected from the group consisting of sodium resoles, potassium resoles, and mixtures thereof.
- 4. The method of claim 2 wherein said curing agent comprises methyl formate.
- 5. The method of claim 2 wherein said curing agent comprises methyl formate.
- 6. The method of claim 2 wherein the amount of said carbonifiable material is in the range of from about 10% to about 30% based on the weight of said aqueous solution of resin.
- 7. The method of claim 2 wherein the amount of said carbonifiable material is from 0.5% to 165% by weight of said aqueous solution of resin.
- 8. The method of claim 2 wherein said aqueous solution of resin has a resin solids content of about 60% and a viscosity of about 200 cP.
- 9. The method of claim 2 wherein said curing compound in liquid form is combined with a heated stream of inert gas to vaporize said curing compound before being brought in contact with said shape.
- 10. The method of claim 2 wherein said curing agent that is brought in contact with said shape is dispersed in a carrier gas as a vapor or as an aerosol and said carrier gas is selected from the group consisting of air, nitrogen, carbon dioxide, and mixtures thereof.
- 11. The method of claim 2 wherein said carbonifiable material is in solution or is dispersed in an organic fluid carrier.
- 12. The method of claim 11 wherein said carbonifiable material is in a solution in a carrier comprising the solvent naphtha.
Parent Case Info
This is a division, of application U.S. Ser. No. 07/295,520, filed 1/11/89, now U.S. Pat. No. 4,980,394.
US Referenced Citations (3)
Number |
Name |
Date |
Kind |
4283319 |
Konii et al. |
Aug 1981 |
|
4468359 |
Lemon et al. |
Aug 1984 |
|
4474904 |
Lemon et al. |
Oct 1984 |
|
Non-Patent Literature Citations (2)
Entry |
Stanbridge et al., "The Replacement of Seacoal in Iron Foundry Molding Sands"; (AFS Trans.), 82, 169-180 (1974). |
Owen et al., "Coaldust Replacement as a Greens a Additive" (British Foundryman), 29-32 (Feb. 1975). |
Divisions (1)
|
Number |
Date |
Country |
Parent |
295520 |
Jan 1989 |
|