High surface area magnesia curing agent
AssigneeBorden Chemical, Inc.
InventorJimmy Pingao Chen
Life of this patent
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Abstract
Binder compositions of the present invention are useful in refractory and foundry applications. The compositions include an aggregate, a liquid resole resin, and a magnesium hardening agent. The compositions are workable and exhibit high compressive strengths in a short period of time. Additionally, the compositions have a low free phenol content and require a reduced resin content as compared to currently known compositions. The compositions reduce the cost to produce useful binders by eliminating, the requirement for ester curing in addition to requiring reduced amounts of resin to obtain adequate compressive strength.
Claims22
A composition comprising:
- a) a liquid resole having a mole ratio of phenol to formaldehyde ranging from about 1:2.0 to about 1:2.4;
- b) an aggregate;
- and
- c) a lightburned magnesium hardening agent.
A binder composition, comprising:
- an aggregate;
- a liquid resole having a mole ratio of phenol to formaldehyde ranging from about 1:2.0 to about 1:2.4, in an amount ranging from about 1% to about 20% by weight, based on the total weight of the aggregate;
- lightburned magnesium oxide in an amount ranging from about 0.5% to about 50% by weight, based on the total weight of the liquid resole.;
- and
- a solvent in an amount ranging from 0% to about 25% by weight, based on the total weight of the aggregate.
A binder composition, comprising:
- magnesium oxide;
- a liquid resole having a mole ratio of phenol to formaldehyde of 1:2.2, in an amount ranging from about 4% to about 10% by weight, based on the total weight of the aggregate;
- lightburned magnesium oxide in an amount ranging from about 8% to about 15% by weight, based on the total weight of the liquid resole.;
- and
- water in an amount ranging from 2% to about 8% by weight, based on the total weight of the aggregate.
A binder composition, comprising:
- silica sand;
- a liquid resole having a mole ratio of phenol to formaldehyde of 1:2.2, in an amount ranging from about 4% to about 10% by weight, based on the total weight of the aggregate;
- lightburned magnesium oxide in an amount ranging from about 12% to about 18% by weight, based on the total weight of the liquid resole.;
- and
- water in an amount ranging from 2% to about 8% by weight, based on the total weight of the aggregate.
Dependencies are inferred from the claim text.