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) until a foundry mix is to be created, where said parts by weight are based upon 100 parts of the binder system.
Claims20
A method of casting a metal article comprising:
- providing an aggregate;
- providing a foundry binder system, wherein the foundry binder system 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 benzene in a range from 0.5 to 10 parts by weight, and an acrylate in a range from 20 to 70 parts by weight, wherein said parts by weight are based upon 100 parts of the foundry binder system;
- and wherein Part One and Part Two are stored separately prior to mixing the foundry binder system with the aggregate;
- mixing the foundry binder system and the aggregate to create a foundry mix;
- introducing the foundry mix into a pattern to form a foundry shape;
- curing the foundry shape to create a cured foundry shape defining a negative space;
- introducing liquid metal into the negative space of the cured foundry shape;
- allowing the liquid metal to cool and solidify to cast a metal article;
- and
- separating the casted metal article from the cured foundry shape.
A method of casting a metal article comprising:
- providing a foundry aggregate;
- providing a foundry binder system including:
- (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;
- and
- (4) 10 to 40 parts by weight of a free radical initiator;
- wherein said parts by weight are based upon 100 parts of the foundry binder system;
- mixing the foundry binder system and the foundry aggregate to create a foundry mix;
- fabricating a foundry shape by introducing the foundry mix into a pattern to form the foundry shape;
- curing the foundry shape to create a cured foundry shape that defines a negative space;
- pouring liquid metal into the negative space of the cured foundry shape;
- allowing the liquid metal to cool and solidify to cast a metal article;
- and
- separating the casted metal article from the cured foundry shape.
A foundry binder system comprising:
- a first portion that includes an epoxy resin in a range from 25 to 70 parts by weight and a free radical initiator in a range from 10 to 40 parts by weight, wherein the epoxy resin of the first portion is a Bisphenol F epoxy resin;
- a second portion that includes an epoxy novolac resin in a range from 10 to 40 parts by weight, an acrylate in a range from 20 to 70 parts by weight, and a polyhydroxy benzene in a range from 0.5 to 10 parts by weight, wherein the polyhydroxy benzene is one of a resorcinol, a non-functionalized resorcinol compound, and a functionalized resorcinol compound;
- wherein said parts by weight are based upon 100 parts of the foundry binder system;
- and
- wherein the first portion and the second portion are stored separately until a foundry mix is to be prepared.
Dependencies are inferred from the claim text.