IP Library › Granted Patent US 7,081,487
Granted Patent B2
US 7,081,487 · App. 10/628,024 · Granted Jul 25, 2006

Cold-box binders containing an epoxy resin and ester of a fatty acid

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Quick Facts
Patent No.
US 7,081,487
App. No.
10/628,024
Filed
Jul 25, 2003
Granted
Jul 25, 2006
Kind
B2
Art Unit
1714
USPC
523/139
Abstract

This invention relates to foundry binder systems, which cure in the presence of sulfur dioxide and an oxidizing agent, comprising (a) an epoxy resin; (b) an ester of a fatty acid; (c) an effective amount of a oxidizing agent, and (d) no ethylenically unsaturated monomer or polymer. The foundry binder systems are used for making foundry mixes. The foundry mixes are used to make foundry shapes (such as cores and molds) which are used to make metal castings, particularly ferrous castings.

Claims (24)

1. A foundry binder system, which will cure in the presence of sulfur dioxide and an oxidizing agent, comprising:

(a) from 45 to 80 parts by weight of an epoxy resin;

(b) from 5 to 40 parts by weight of ester of a fatty acid;

(c) from 10 to 40 parts by weight of an oxidizing agent; and

(d) 0 parts of an ethylenically unsaturated monomer or polymer,

wherein (a), (b), and (c) are separate components or mixed with another of said components, and where said parts by weight are based upon 100 parts of binder.

2. The binder system of claim 1 wherein the epoxy resin is selected from the group consisting of epoxy resins derived from bisphenol A, epoxy resins derived from bisphenol F, epoxidized novolac resins, cycloaliphatic epoxy resins, and mixtures thereof.

3. The binder system of claim 2 wherein the epoxy resin has an epoxide equivalent weight of about 165 to about 225 grams per equivalent.

4. The foundry binder system of claim 3 wherein the epoxy resin comprises a cycloaliphatic epoxy resin.

5. The binder system of claim 4 wherein the oxidizing agent is cumene hydroperoxide.

6. The foundry binder system of claim 5 wherein the amount of epoxy resin is from 50 to 70 parts by weight, the amount of ester of a fatty acid is from 15 to 30 parts by weight, and the amount of amount of a oxidizing agent is from 12 to 30 parts by weight, where the weights are based upon 100 parts of the binder system and the components of said binder system are packaged as mixture.

7. A foundry mix comprising:

(a) a major amount of foundry aggregate;

(b) an effective bonding amount of the foundry binder system of claim 1 , 2 , 3 , 4 , 5 , or 6 .

8. A cold-box process for preparing a foundry shape comprising:

(a) introducing the foundry mix of claim 7 into a pattern; and

(b) curing with gaseous sulfur dioxide.

9. A foundry shape prepared in accordance with claim 8 .

10. A process of casting a metal article comprising:

(a) fabricating an foundry shape in accordance with claim 8 ;

(b) pouring said metal while in the liquid state into said foundry shape;

(c) allowing said metal to cool and solidify; and

(d) then separating the molded article.

11. A casting prepared in accordance with claim 10 .