Catalysts and binder systems for manufacturing sandshapes

Abstract

A catalyst material is described, particularly useful in making core sand from which resin bound sand shapes are made. The preferred catalyst is a material comprising at least one salt made from a weak base and an acid from the group comprising lower aliphatic and aromatic hydrocarbon sulfonic acids. The curable resin binder is preferably a furfuryl alcohol polymer or other furan-based material. The resin is preferably present in an amount of about 0.5% to about 5% based on the weight of sand, while the catalyst is present in an amount of about 5% to 40% by weight of the resin material. The catalyzed composition provides an excellent combination of working or bench life, rapid curing on a delayed action basis and favorable shape-imparting and holding properties in the formed sand shapes. Specifically preferred compositions include aluminum and copper phenol and toluene sulfonic acid salts.

Dependencies are inferred from the claim text.