# US 11,027,328 B2 · Refractory coating composition for making facings on temporary molds or on cores for iron and steel casting operations > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,027,328 B2 - Document ID: US11027328B2 - Status: Granted - Kind: B2 - Application number: 16/313,960 - Filed: 2017-06-29 - Published: 2019-07-25 - Granted: 2021-06-08 - Earliest claimed: 2016-06-30 - Assignees: HüTtenes-Albertus Chemische Werke Gesellschaft Mit BeschräNkter Haftung - Applicants: HüTtenes-Albertus Chemische Werke Gesellschaft Mit BeschräNkter Haftung - Inventors: René Höft - Web page: https://patentgrep.com/patent/US11027328B2 ## CPC - B22C 3/00: Selection of compositions for coating the surfaces of moulds, cores, or patterns - B22C 9/02: Sand moulds or like moulds for shaped castings - C09D 1/00: Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances - B22C: FOUNDRY MOULDING (moulding refractory materials in general B28B) - C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D) ## Abstract The invention relates to a refractory coating composition for producing mold coatings on non-permanent molds or on cores for the casting of iron and steel, comprising a) an alkali metal salt or alkaline earth metal salt of carbonic acid and/or an alkali metal salt or alkaline earth metal salt of diphosphoric acid, b) a carrier liquid and c) refractory materials. ## Claims ### Claim 1 A refractory coating composition for producing mold coatings on non-permanent molds or on cores for the casting of iron and steel, comprising a) 0.5 to 30% by weight of an alkali metal salt or alkaline earth metal salt of diphosphoric acid, based on the total weight of the refractory coating composition and 0.5 to 30% by weight of an alkali metal salt or alkaline earth metal salt of carbonic acid, based on the total weight of the refractory coating composition, or 0.5 to 30% by weight of an alkali metal salt or alkaline earth metal salt of hydrogencarbonate, based on the total weight of the refractory coating composition, or 0.5 to 30% by weight of an alkali metal salt or alkaline earth metal salt of dihydrogendiphosphate, based on the total weight of the refractory coating composition, b) a carrier liquid and c) refractory materials, wherein the solids content of the refractory coating composition is from 10 to 85% by weight. ### Claim 2 (depends on 1) The refractory coating composition as claimed in claim 1, comprising the alkali metal salt or alkaline earth metal salt of diphosphoric acid and the alkali metal salt or alkaline earth metal salt of carbonic acid. ### Claim 3 (depends on 2) The refractory coating composition as claimed in claim 2, wherein the refractory coating composition comprises: a molar ratio between the alkali metal salt or alkaline earth metal salt of carbonic acid and the alkali metal salt or alkaline earth metal salt of diphosphoric acid in the range from 1:26 to 10:2.6; and/or a pH of from 7 to 9.9. ### Claim 4 (depends on 2) The refractory coating composition as claimed in claim 2 wherein the alkali metal salt or alkaline earth metal salt of carbonic acid is a primary or secondary carbonate. ### Claim 5 (depends on 2) The refractory coating composition as claimed in claim 2, wherein the refractory coating composition has a molar ratio between the alkali metal salt or alkaline earth metal salt of carbonic acid and the alkali metal salt or alkaline earth metal salt of diphosphoric acid in the range from 1:13 to 5:2.6. ### Claim 6 (depends on 1) The refractory coating composition as claimed in claim 1, wherein the refractory coating composition is a covering refractory coating. ### Claim 7 (depends on 1) The refractory coating composition as claimed in claim 1, wherein the alkali metal salt or alkaline earth metal salt of carbonic acid is sodium hydrogencarbonate or sodium carbonate. ### Claim 8 (depends on 1) The refractory coating composition as claimed in claim 1, comprising (a) from 3 to 50% by weight of the alkali metal salt or alkaline earth metal salt of carbonic acid, based on the total weight of the refractory coating composition, and/or (b) from 3 to 50% by weight of the alkali metal salt or alkaline earth metal salt of diphosphoric acid, based on the total weight of the refractory coating composition. ### Claim 9 (depends on 1) The refractory coating composition as claimed in claim 1, wherein the carrier liquid a) is water or contains water and/or b) is one or more organic solvents or contains these, where one or all at least one of the organic solvents is/are alcohol or alcohols. ### Claim 10 (depends on 1) The refractory coating composition as claimed in claim 1, wherein the carrier liquid is an alcohol or contains alcohol. ### Claim 11 (depends on 1) The refractory coating composition as claimed in claim 1, comprising a) from 3 to 15% by weight of sodium hydrogencarbonate and/or sodium carbonate and from 3 to 15% by weight of disodium dihydrogendiphosphate, in each case based on the total weight of the refractory coating composition, b) a carrier liquid selected from the group consisting of water, ethanol, 1-propanol, 2-propanol and mixtures thereof, c) refractory materials selected from the group consisting of silica, aluminum oxide, zirconium dioxide, aluminum silicates, mullite, zircon sands, zirconium silicates, olivine, talc, mica, coke, feldspar, diatomite, calcined kaolins, kaolinite, metakaolinite, magnesium silicates, iron oxide, bauxite, graphite and mixtures thereof, where the refractory coating composition has a pH of from 7 to 9.9, and the weight ratio between a) sodium hydrogencarbonate or sodium carbonate and b) disodium dihydrogendiphosphate is in the range from 1:10 to 10:1. ### Claim 12 (depends on 1) The refractory coating composition as claimed in claim 1, wherein the refractory coating composition has a pH of from 7.5 to 9.5. ### Claim 13 (depends on 1) The refractory coating composition as claimed in claim 1, wherein the carrier liquid is an alcohol selected from the group consisting of methanol, ethanol, 1-propanol, 2-propanol, n-butanol, isobutanol, sec-butanol, tert-butanol, pentan-1-ol, pentan-2-ol, pentan-3-ol, 2-methylbutan-1-ol, 2-methylbutan-2-ol, 3-methylbutan-1-ol, 3-methylbutan-2-ol, 2,2-dimethylpropan-1-ol, hexan-1-ol, hexan-2-ol, hexan-3-ol, 2-methylpentan-l-ol, 3-methylpentan-l-ol, 4-methylpentan-1-ol, 2-methylpentan-2-ol, 3-methylpentan-2-ol, 4-methylpentan-2-ol, 2-methylpentan-3-ol, 3-methylpentan-3-ol, 2,2-dimethylbutan-1-ol, 2,3-dimethylbutan-1-ol, 3,3-dimethylbutan-1-ol, 2,3-dimethylbutan-2-ol, 3,3-dimethylbutan-2-ol, 2-ethylbutan-1-ol, and mixtures thereof. ### Claim 14 (depends on 1) The refractory coating composition as claimed in claim 1, wherein the alkali metal salt or alkaline earth metal salt of carbonic acid is a primary or secondary carbonate. ### Claim 15 (depends on 1) The refractory coating composition as claimed in claim 1, wherein the refractory coating composition comprises: a molar ratio between the alkali metal salt or alkaline earth metal salt of carbonic acid and the alkali metal salt or alkaline earth metal salt of diphosphoric acid in the range from 1:26 to 10:2.6; and/or a pH of from 7 to 9.9. ### Claim 16 (depends on 1) The refractory coating composition as claimed in claim 1, comprising 0.5 to 30% by weight of disodium dihydrogendiphosphate, based on the total weight of the refractory composition and 0.5 to 30% by weight of an alkali metal salt or alkaline earth metal salt of carbonic acid, based on the total weight of the refractory composition, or 0.5 to 30% by weight of disodium dihydrogendiphosphate, based on the total weight of the refractory composition. ### Claim 17 (depends on 1) A method of coating non-permanent molds or cores for the casting of iron and steel, comprising: providing or producing a refractory coating composition as claimed in claim 1. ### Claim 18 (depends on 1) A process for producing a casting, comprising the following steps: (i) providing or producing a casting mold composed of chemically bound base mold material, (ii) coating at least one region of the casting mold with a refractory coating composition as defined in claim 1 and drying of the coated refractory coating composition, (iii) filling the casting mold with a molten iron-carbon alloy, (iv) allowing the iron-carbon alloy to solidify in the casting mold so as to result in a casting.