Lithium-containing resole composition for making a shaped refractory article and other hardened articles
AssigneeBorden, Inc.
InventorArthur H. Gerber
Life of this patent
Estimating the term…
Abstract
The invention relates to the use of lithium ion-generating alkalizing agents in resole binder compositions useful for bonding aggregate materials to form refractory articles. Use of lithium-ion generating alkalizing agents produce resole resin binder compositions which, when cured by an ester functional curing agent, exhibit tensile and compression strengths superior to strengths obtained from compositions using sodium ion-generating or potassium ion-generating alkalizing agents.
Claims34
A curable binder composition comprising
- (a) a phenol formaldehyde resole resin;
- (b) an ester-functional curing agent in an amount sufficient to effect the ambient temperature cure of the resole resin;
- and,
- (c) a lithium ion-generating alkalizing agent present in an amount sufficient to produce in the composition a mole ratio of lithium:phenol of from about 0.1:1 to about 1:1.
A binder-aggregate material comprising (a) a phenol formaldehyde resole resin;
- (b) an ester-functional curing agent in an amount sufficient to effect the ambient temperature cure of the resole resin;
- (c) a lithium ion-generating alkalizing agent present in an amount sufficient to produce in the composition a mole ratio of lithium:phenol of from about 0.1:1 to about 1:1;
- and (d) a particulate aggregate material, wherein the weight ratio of resole resin to aggregate material is from about 2:100 to about 1:7.
A shaped article for use in making a refractory article comprising aggregate material bonded together by a cured binder composition, said binder composition in its uncured state comprising a phenol formaldehyde resole resin, an ester-functional curing agent, and a lithium ion-generating alkalizing agent selected from the group consisting of lithium oxide, lithium hydroxide, lithium methoxide, lithium ethoxide, monolithium salt of ethylene glycol, and mixtures thereof, wherein the lithium ion-generating alkalizing agent is present in an amount sufficient to produce in the binder composition a mole ratio of lithium:phenol of from about 0.1:1 to about 1:1, and the ester-functional curing agent is present in an amount sufficient to cure at ambient temperature the resole resin and wherein the aggregate material is selected from the group consisting of magnesia, alumina, silica, zirconia, zircon sand, olivine sand, silicon carbide, silicon nitride, boron nitride, bauxite, corundum, pumice, perlite, vermiculite, limestone, quartz, sand, gravel, crushed rock, broken brick, air cooled blast furnace slag, and mixtures thereof.
A shaped article comprising
- (a) a phenol formaldehyde resin binder composition comprising in its uncured state
- (i) a phenol formaldehyde novolac resin having a formaldehyde:phenol mole ratio in the range of about 0.5:1 to about 0.9:1, and
- (ii) a phenol formaldehyde resole resin having a formaldehyde:phenol mole ratio in the range of about 1:1 to about 3:1,
- wherein said novolac and said resole resins are present in a weight ratio of novolac to resole of between about 5:1 and about 0.35:1 and wherein the phenol is selected from the group consisting of phenol, cresol and xylenol;
- (b) an ester-functional curing agent;
- (c) lithium oxide alkalizing agent;
- and
- (d) an aggregate material selected from the group consisting of silica, alumina and magnesia present in an amount up to 97% by weight of the shaped article,
- and wherein the pH of the resin binder composition is sufficiently alkaline to cure the resin binder composition, at ambient temperature, and bind the aggregate material into a desired shape.
Dependencies are inferred from the claim text.