# US 2019/0168289 A1 · Compositions and Methods for Modified Ester-Curatives and Reduction of Formaldehyde Emission and Odor in Ester-Cured Phenolic Binder Systems > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2019/0168289 A1 - Document ID: US20190168289A1 - Status: Published application - Kind: A1 - Application number: 16/273,369 - Filed: 2019-02-12 - Published: 2019-06-06 - Earliest claimed: 2015-12-18 - Assignees: HA-International, LLC - Applicants: HA-International, LLC - Inventors: Sudhir K. Trikha - Web page: https://patentgrep.com/patent/US20190168289A1 ## CPC - B22C 1/2253: {with phenols} - C08K 5/13: Phenols; Phenolates - C08L 61/06: of aldehydes with phenols - B22C: FOUNDRY MOULDING (moulding refractory materials in general B28B) - C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09) - C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06) ## Abstract This invention relates to compositions and methods for reduction of formaldehyde odor and emission during the production and curing of cores and molds, particularly those cores and molds of the foundry industry which comprise ester curable phenolic binders. More specifically, included herein is an ester-curative comprising an ester and resorcinol which, when provided in a composition with a resin and an aggregate, effectively scavenges unreacted formaldehyde thereby reducing emission and odor of the same from the composition. ## Claims ### Claim 1 A method for reducing formaldehyde emissions from ester-cured foundry binders used in the formation of foundry molds and cores, the method comprising the steps of: (a) combining an aggregate with a water soluble alkaline phenolic resole resin to form a first admixture; (b) combining an ester-curative with resorcinol to form a modified ester-curative; and (c) combining the first admixture with the modified ester-curative to form a second admixture; wherein the modified ester-curative is configured to affect a reduced emission of formaldehyde from the second admixture. ### Claim 2 (depends on 1) The method of claim 1, wherein the resin comprises about 5% to about 10% sodium hydroxide by weight of the resin. ### Claim 3 (depends on 1) The method of claim 1, wherein the ratio of ester-curative to resorcinol ranges from about 19:1 to about 99:1 by weight of the modified ester-curative. ### Claim 4 (depends on 3) The method of claim 3, wherein the resin comprises about 5% to about 10% sodium hydroxide by weight of the resin. ### Claim 5 (depends on 1) The method of claim 1, wherein the resin has a pH of approximately 13 or greater. ### Claim 6 (depends on 1) The method of claim 1, wherein the ester-curative comprises about 20% to about 30% glycerol triacetate by weight of the ester-curative. ### Claim 7 (depends on 6) The method of claim 6, wherein the ester-curative further comprises about 70% to about 80% dibasic ester by weight of the ester-curative. ### Claim 8 (depends on 6) The method of claim 6, wherein the ratio of ester-curative to resorcinol ranges from about 19:1 to about 99:1 by weight of the modified ester-curative. ### Claim 9 (depends on 8) The method of claim 8, wherein the ratio of ester-curative to resorcinol is about 19:1. ### Claim 10 (depends on 1) The method of claim 1, wherein the ester-curative comprises about 70% to about 80% dibasic ester by weight of the ester-curative. ### Claim 11 (depends on 10) The method of claim 10, wherein the ratio of ester-curative to resorcinol ranges from about 19:1 to about 99:1 by weight of the modified ester-curative. ### Claim 12 (depends on 11) The method of claim 11, wherein the ratio of ester-curative to resorcinol is about 19:1. ### Claim 13 (depends on 1) The method of claim 1, wherein the ester-curative comprises about 90% to about 100% glycerol triacetate by weight of the ester-curative. ### Claim 14 (depends on 13) The method of claim 13, wherein the ratio of ester-curative to resorcinol ranges from about 19:1 to about 99:1 by weight of the modified ester-curative. ### Claim 15 (depends on 14) The method of claim 14, wherein the ratio of ester-curative to resorcinol is about 32:1. ### Claim 16 (depends on 1) The method of claim 1, wherein the ester-curative comprises about 30% propylene carbonate by weight of the ester-curative and about 70% gamma butyrolactone by weight of the ester-curative. ### Claim 17 (depends on 16) The method of claim 16, wherein the ratio of ester-curative to resorcinol ranges from about 19:1 to about 99:1 by weight of the modified ester-curative. ### Claim 18 (depends on 17) The method of claim 17, wherein the ratio of ester-curative to resorcinol is about 19:1. ### Claim 19 (depends on 1) The method of claim 1, further comprising the steps of: (d) placing the second admixture into a housing; and (e) allowing the second admixture to cure; wherein the ratio of ester-curative to resorcinol ranges from about 19:1 to about 99:1 by weight of the modified ester-curative; and wherein the resin has a pH of approximately 13 or greater. ### Claim 20 A method for reducing formaldehyde emissions from ester-cured foundry binders used in the formation of foundry molds and cores, the method comprising the steps of: (a) combining an aggregate with a water soluble alkaline phenolic resole resin to form a first admixture; (b) combining an ester-curative with resorcinol to form a modified ester-curative; and (c) combining the first admixture with the modified ester-curative to form a second admixture; wherein the resin comprises about 5% to about 10% sodium hydroxide by weight of the resin, and the resin has a pH of approximately 13 or greater; wherein the ester curative-curative comprises about 20% to about 100% glycerol triacetate by weight of the ester-curative; wherein the ratio of ester-curative to resorcinol ranges from about 19:1 to about 99:1 by weight of the modified ester-curative; wherein the modified ester-curative is configured to affect a reduced emission of formaldehyde from the second admixture.