FOUNDRY BINDER COMPRISING ONE OR MORE CYCLOALKANES AS A SOLVENT

1 . A foundry binder comprising:

(a) a polyol component selected from the group consisting of phenolic resins, polyether polyols, polyester polyols, amine polyols, and mixtures thereof,

(b) a polyisocyanate component; and

wherein component (a) and/or component (b) further comprise, as a solvent, one or more cycloalkanes selected from the group consisting of unsubstituted cycloalkanes, substituted cycloalkanes, and mixtures thereof.

2 . The foundry binder of claim 1 wherein the polyol component comprises a phenolic resole resin.

3 . The foundry binder of claim 2 wherein the number of carbon atoms in the cycloalkane is from 5 to 24.

4 . The foundry binder of claim 3 wherein the number of rings in the cycloalkane is from 1 to 4.

5 . The foundry binder of claim 3 wherein the number of carbon atoms in the rings of the cycloalkanes is from 4 to 10.

6 . The foundry binder of claim 5 wherein one or more of the cycloalkanes has 2 rings.

7 . The foundry binder of claim 2 wherein the cycloalkane is selected from the group consisting of cylcohexane, trimethyl cyclohexane, decahydronaphthalene, tetrahydronaphthalene, and mixtures thereof.

8 . The foundry binder of claim 2 wherein the cycloalkane comprises decahydronaphthalene.

9 . The foundry binder of claim 1 , 2 , 3 , 4 , 5 , 6 , 7 , or 8 wherein component (a) and/or component (b) further comprise one or more solvents selected from the group consisting of aromatic hydrocarbon solvents, ester solvents, fatty acid ester solvents, and mixtures thereof.

10 . The foundry binder of claim 9 wherein the amount of cycloalkane in the binder system is from 5 to 40 parts by weight based upon 100 parts by weight of the binder.

11 . The foundry binder of claim 10 wherein the amount of aromatic hydrocarbon solvents is less than 10 parts by weight based upon 100 parts by weight of the binder.

12 . The foundry binder of claim 11 wherein the binder does not contain aromatic hydrocarbon solvents.

13 . A foundry mix comprising a major amount of a refractory and a minor amount of the foundry binder of claim 9 .

14 . The foundry mix of claim 13 which further comprises a liquid tertiary amine curing catalyst.

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

(a) introducing a major amount of the composition of claim 9 into a pattern to form a shape;

(b) contacting the shape with the vapor of a tertiary amine curing catalyst;

(c) allowing the shape to cure; and

(d) removing the shape from the pattern.

16 . A process for casting a metal part comprising:

(a) inserting a foundry shape prepared in accordance with claim 15 into a casting assembly having one or more molds and/or cores;

(b) pouring metal, while in the liquid state, into said casting assembly;

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

(d) then separating the cast metal part from said casting assembly.

17 . A metal casting made by the process of claim 16 .

18 . A no-bake process for preparing a foundry shape comprising:

(a) introducing a major amount of the composition of claim 14 into a pattern to form a shape;

(b) allowing the shape to cure; and

(c) removing the shape from the pattern.

19 . A process for casting a metal part comprising:

(a) inserting a foundry shape prepared in accordance with claim 18 into a casting assembly having one or more molds and/or cores;

(b) pouring metal, while in the liquid state, into said casting assembly;

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

(d) then separating the cast metal part from said casting assembly.

20 . A metal casting made by the process of claim 19 .

21 . A heat cured process for preparing a foundry shape comprising:

(a) introducing a major amount of foundry mix comprising a (i) refractory, (ii) a novolak resin and (iii) a polyisocyanate into a heated pattern to form a foundry shape,

wherein component (ii) and/or component (iii) further comprise, as a solvent, one or more cycloalkanes selected from the group consisting of unsubstituted cycloalkanes, substituted cycloalkanes, and mixtures thereof;

(b) allowing the foundry shape to cure; and

(c) removing the foundry shape from the pattern when it is handleable.