Foundry mix including resorcinol
AssigneeNovis Works, LLC
InventorsJames T. Schneider, Frances Trenta
Life of this patent
Estimating the term…
Abstract
A foundry mix includes a major amount of a foundry aggregate and an effective binding amount of a binder system. The binder system cures in the presence of sulfur dioxide and a free radical initiator. The binder system may include (1) 10 to 70 parts by weight of an epoxy novolac resin; (2) 0.5 to 10 parts by weight of resorcinol; (3) 20 to 70 parts by weight of a monomeric or polymeric acrylate; and (4) an effective amount of a free radical initiator. Notably, (1), (2), (3) and (4) are separate components or mixed with another of said components, provided (4) is not mixed with (3), where said parts by weight are based upon 100 parts of the binder system.
Claims21
A method of casting a metal article comprising:
- fabricating a foundry shape by introducing a foundry mix into a pattern to form the foundry shape;
- wherein the foundry mix includes:
- a first portion (Part One), wherein Part One includes an epoxy resin in a range from 25 to 70 parts by weight and a free radical initiator;
- a second portion (Part Two), wherein Part Two includes an epoxy novolac resin in a range from 10 to 40 parts by weight, a polyhydroxy benezene in a range from 0.5 to 10 parts by weight, an acrylate in a range from 20 to 70 parts by weight and a diabasic ester in a range of 2 to 10 parts by weight;
- provided Part One is not mixed with Part Two prior to or simultaneous to fabricating the foundry shape the foundry mix, and where said parts by weight are based upon 100 parts of the foundry mix;
- curing the shape with gaseous sulfur dioxide;
- pouring metal while in a liquid state into the foundry shape;
- allowing the metal to cool and solidify;
- and
- separating the fabricated shape from the pattern.
A method of casting a metal article comprising:
- providing a foundry aggregate;
- fabricating a foundry shape by introducing a foundry mix comprising an aggregate and a binder system into a pattern to form a foundry shape, wherein the binder system comprises:
- (1) 10 to 70 parts by weight of an epoxy novolac resin;
- (2) 0.5 to 10 parts by weight of a polyhydroxy benzene;
- (3) 20 to 70 parts by weight of a monomeric or polymeric acrylate;
- (4) 2 to 10 parts by weight of a dibasic ester;
- and
- (5) a free radical initiator;
- and where said parts by weight are based upon 100 parts of the foundry mix;
- mixing parts (1), (2), (3), (4), and (5) within the pattern;
- curing said shape with gaseous sulfur dioxide;
- pouring said metal while in a liquid state into said foundry shape;
- allowing said metal to cool and solidify;
- and
- separating the now fabricated shape from the pattern.
Dependencies are inferred from the claim text.