Lignite-urethane based resins for enhanced foundry sand performance
AssigneeAMCOL International Corporation
InventorsJoseph M. Fuqua, Paul Klein
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Abstract
Described herein, in a preferred embodiment, is a leonardite-based polyurethane resin binder that may be used, among other applications, as a binder in combination with foundry aggregate, e.g., sand, for molding or casting metal parts. The binders described herein comprise a humic substance, preferably leonardite, first mixed with a foundry aggregate and then the humic-aggregate mixture is combined with a polymerizable polyol, an isocyanate, and a polymerization catalyst to make a polyurethane resin binder in situ in a foundry aggregate, such as sand. The lignite is added as a solid to the foundry aggregate, and improves the binder performance of the lignite-containing part of the binder components.
Claims17
An article of manufacture comprising:
- a metal casting;
- wherein the metal casting was made by a process comprising pouring a liquid metal into a foundry shape;
- wherein the foundry shape was made from a foundry mix;
- wherein the foundry mix was manufactured by:
- admixing a lignite and a foundry aggregate to form a impregnated foundry aggregate;
- admixing a polymerizable polyol with the impregnated foundry aggregate;
- admixing a polymerizable isocyanate with the impregnated foundry aggregate;
- and
- admixing a polymerization catalyst with the impregnated foundry aggregate.
A method of making a metal casting comprising:
- admixing an organic solid and a foundry aggregate to form a impregnated foundry aggregate,
- admixing a polymerizable polyol with the impregnated foundry aggregate,
- admixing a polymerizable isocyanate with the impregnated foundry aggregate, and
- admixing a polymerization catalyst with the impregnated foundry aggregate;
- to yield a foundry mix.
A foundry shape comprising a foundry aggregate, a lignite, and a urethane resin;
- wherein the urethane resin is admixed with an impregnated foundry aggregate that comprises a mixture of the foundry aggregate and the lignite.
A process of preparing a foundry shape comprising homogeneously mixing a impregnated foundry aggregate, a polymerizable polyol, a polymerizable isocyanate, and a catalysts to form a moldable mixture and forming the moldable mixture into a foundry mold or core.
Dependencies are inferred from the claim text.