Binder composition for making foundry molds

Patent metadata

Field	Value
Publication number	US-9636742-B2
Application number	US-201314387111-A
Country	US
Kind code	B2
Filing date	Mar 12, 2013
Priority date	Mar 23, 2012
Publication date	May 2, 2017
Grant date	May 2, 2017

Abstract

A binder composition for making foundry molds, comprising an acid-hardening resin, one or more 5-position-substituted-furfural compounds selected from the group consisting of 5-hydroxymethylfurfural and 5-acetoxymethylfurfural, and one or more compounds selected from the group consisting of urea and derivatives of urea, wherein the content of the 5-position-substituted-furfural compound(s) by percentage is from 1 to 60% by weight of the binder composition. The content of the compound(s) by percentage selected from the group consisting of urea and derivatives of urea is preferably from 0.3 to 10% by weight of the binder composition.

First claim

The invention claimed is:

1. A binder composition for making foundry molds, comprising:
an acid-hardening resin;
one or more 5-position-substituted-furfural compounds selected from the group consisting of 5-hydroxymethylfurfural and 5-acetoxymethylfurfural; and
one or more compounds selected from the group consisting of urea, alkylene ureas, alkyl ureas, cyclohexyl ureas, aryl ureas, hydroxyalkyl ureas having two or more carbon atoms in the alkyl group, and azodicarbonamide, wherein
the content of the 5-position-substituted-furfural compound(s) is from 10 to 50% by weight of the binder composition,
the content of the compound(s) selected from the group consisting of urea, alkylene ureas, alkyl ureas, cyclohexyl ureas, aryl ureas, hydroxyalkyl ureas having two or more carbon atoms in the alkyl group, and azodicarbonamide is from 1 to 8% by weight of the binder composition, and
the binder composition further comprises water.

2. The binder composition for making foundry molds according to claim 1 , wherein the ratio by weight of the 5-position-substituted-furfural compound(s) to the compound(s) selected from the group consisting of urea, alkylene ureas, alkyl ureas, cyclohexyl ureas, aryl ureas, hydroxyalkyl ureas having two or more carbon atoms in the alkyl group, and azodicarbonamide is from 3 to 40.

3. The binder composition for making foundry molds according to claim 1 , wherein the content of the acid-hardening resin by percentage is from 10 to 98% by weight of the binder composition.

4. The binder composition for making foundry molds according to claim 1 , wherein the acid-hardening resin is one or more selected from the group consisting of furfuryl alcohol, any condensate from furfuryl alcohol, any condensate from a phenolic compound and an aldehyde, and any condensate from furfuryl alcohol, urea and an aldehyde.

5. The binder composition for making foundry molds according to claim 1 , wherein the compound(s) selected from the group consisting of urea, alkylene ureas, alkyl ureas, cyclohexyl ureas, aryl ureas, hydroxyalkyl ureas having two or more carbon atoms in the alkyl group, and azodicarbonamide is one or more selected from the group consisting of alkylene ureas and alkyl ureas.

6. The binder composition for making foundry molds according to claim 1 , wherein the compound(s) selected from the group consisting of urea, alkylene ureas, alkyl ureas, cyclohexyl ureas, aryl ureas, hydroxyalkyl ureas having two or more carbon atoms in the alkyl group, and azodicarbonamide is one or more selected from the group consisting of urea and ethylene urea.

7. The binder composition for making foundry molds according to claim 1 , further comprising 2,5-bis(hydroxymethyl)furan.

8. The binder composition for making foundry molds according to claim 7 , wherein the content of 2,5-bis(hydroxymethyl)furan by percentage is from 0.5 to 30% by weight of the binder composition.

9. The binder composition for making foundry molds according to claim 1 , further comprising resorcin.

10. The binder composition for making foundry molds according to claim 9 , wherein the content of resorcin by percentage is from 1 to 10% by weight of the binder composition.

11. The binder composition for making foundry molds according to claim 1 , wherein the content of water by percentage is from 0.5 to 30% by weight of the binder composition.

12. A composition for a mold, wherein the following are mixed with each other: refractory particles; the binder composition for making foundry molds recited in claim 1 ; and a hardener for hardening the binder composition for making foundry molds.

13. A method for producing a mold, comprising the step of hardening the composition for a mold recited in claim 12 .

14. A binder composition for making foundry molds, comprising:
an acid-hardening resin, one or more 5-position-substituted-furfural compounds selected from the group consisting of 5-hydroxymethylfurfural and 5-acetoxymethylfurfural, and
one or more compounds selected from the group consisting of alkylene ureas and alkyl ureas, wherein
the content of the 5-position-substituted-furfural compound(s) is from 1 to 60% by weight of the binder composition.

Assignees

• Kao Corp

Inventors

• Joke Takashi
• Matsuo Toshiki

Classifications

• B22C1/224 Primary

  Furan polymers (B22C1/2273 takes precedence) · CPC title

• C08L71/14

  Furfuryl alcohol polymers · CPC title

• B22C1/181

  Cements, oxides or clays · CPC title

• B22C1/2253 Primary

  with phenols · CPC title

• C08K5/1535

  Five-membered rings · CPC title