GB2085453A - Furfuryl alcohol resin-wood resin binder compositions - Google Patents
Furfuryl alcohol resin-wood resin binder compositions Download PDFInfo
- Publication number
- GB2085453A GB2085453A GB8126662A GB8126662A GB2085453A GB 2085453 A GB2085453 A GB 2085453A GB 8126662 A GB8126662 A GB 8126662A GB 8126662 A GB8126662 A GB 8126662A GB 2085453 A GB2085453 A GB 2085453A
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- GB
- United Kingdom
- Prior art keywords
- resin
- binder composition
- composition according
- formaldehyde
- furfuryl alcohol
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
- B22C1/16—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents
- B22C1/20—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of organic agents
- B22C1/22—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of organic agents of resins or rosins
- B22C1/2233—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of organic agents of resins or rosins obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L61/00—Compositions of condensation polymers of aldehydes or ketones; Compositions of derivatives of such polymers
- C08L61/34—Condensation polymers of aldehydes or ketones with monomers covered by at least two of the groups C08L61/04, C08L61/18 and C08L61/20
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L71/00—Compositions of polyethers obtained by reactions forming an ether link in the main chain; Compositions of derivatives of such polymers
- C08L71/08—Polyethers derived from hydroxy compounds or from their metallic derivatives
- C08L71/14—Furfuryl alcohol polymers
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- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Health & Medical Sciences (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Mold Materials And Core Materials (AREA)
Abstract
A binder composition suitable for use in the production of cores or moulds for metal casting comprises furfuryl alcohol and a furfuryl alcohol soluble resin produced from coniferous wood. Glyoxal, formaldehyde, a urea-formaldehyde resin or precondensate a phenol-formaldehyde resole resin, a diluent liquid and/or a silane can also be included.
Description
SPECIFICATION
Binder compositions
This invention relates to binder compositions, and particularly to binder compositions used to bond particulate refractory material such as sand in the production of cores and moulds for metal casting.
It is known to use a resin derived from southern pinewood sold under the trade name VINSOL as a part replacement for phenolic novolak resin in so-called shell moulding compositions. The
VINSOL resin may be modified by reaction with furfuraldehyde prior to blending in the molten state with the phenolic novolak resin.
We have now found that resins derived from coniferous wood are particularly useful in binder compositions based on furfuryl alcohol used for making foundry moulds and cores.
According to the invention there is provided a binder composition comprising furfuryl alcohol and a resin produced from coniferous wood and soluble in furfuryl alcohol.
The following are examples of resins produced from coniferous wood which are commercially available and which are suitable for use in the binder compositions of the invention: (1) VINSOL resin, a substantially aliphatic hydrocarbon-insoluble material produced by extract
ing pinewood with a coal tar hydrocarbon, evaporating the extract to produce a solid
residue, separating a resin extract from the solid residue and recovering the remaining
residue.
(2) RESPIN and RESMOL resins, natural resins derived from Araucaria Angustifolia (also
known as Brazilian pine.) These resins are crystalline, light-brown coloured thermoplastic
resins having a high melting point.
(3) PENBRO resin, a material which is partially soluble in aliphatic hydrocarbons, and which
like VINSOL resin is obtained from the oleoresinous constituents of sourthern pinewood.
Curable binder compositions may be produced from a solution of the coniferous wood resin in furfuryl alcohol but if desired other constituents such as glyoxal, formaldehyde or a formaldehyde-containing resin such as a urea-formaldehyde or a phenol-formaldehyde resin may also be included.
The preferred compositions according to the invention comprises furfuryl alcohol, furfuryl alcohol-soluble coniferous wood resin and urea-formaldehyde resin or precondensate and/or phenol-formaldehyde resole resin. When used in a UF furane or PF furane the coniferous wood resin acts as an extender for the more costly furfuryl alcohol and up to about 30% by weight of the furfuryl alcohol content of a particular binder composition may be replaced by the coniferous wood resin. Preferably 10-15% by weight of the furfuryl alcohol may be replaced by the coniferous wood resin.
In order to promote adhesion of the binder composition to a sand substrate it may be desirable to include in the composition a silane such as gamma-aminopropyltriethoxy silane (H2NCH2CH2CH2Si(OC2H5)3) or other aminofunctional silane. When used the silane will usually be employed in an amount of from 0.05 to 0.5% by weight of the binder composition.
A diluent liquid such as water or an alcohol, for example methanol, may also be included in the composition.
The binder compositions according to the invention will usually contain the following components in the following proportions by weight:
Furfuryl alcohol 1 5-9 5% Coniferous wood resin 5-30%
Phenol-formaldehyde resole resin 0-60%
Urea-formaldehyde resin or precondensate 0-70%
Glyoxal or formaldehyde 0-20%
Diluent liquid 0-35%
When the composition contains only furfuryl alcohol and coniferous wood resin and optionally a diluent liquid the preferred proportions are, by weight:
Furfuryl alcohol 70-95% Coniferous wood resin 5-30%
Diluent liquid 0-10% When the composition contains glyoxal or formaldehyde the preferred proportions are, by weight::
Furfuryl alcohol 50-90%
Coniferous wood resin 5-30%
Glyoxal or formaldehyde 5-20%
Diluent liquid 0-10% When the composition contains a phenol-formaldehyde resole resin and/or a urea-formaldehyde resin or precondensate the preferred proportions are, by weight:
Furfuryl alcohol 15-90% Coniferous wood resin 5-30%
Phenol-formaldehyde resole resin 0-60%
Urea-formaldehyde resin or precondensate 0-70%
Diluent liquid 0-30%
Various proprietary brands and grades of coniferous wood resin are available but the preferred material is a flake form of RESPIN resin which is readily dissolved in furfuryl alcohol at ambient temperature.Such a material enables, for example, a modified urea-formaldehyde furane resin composition to be produced by cold blending furfuryl alcohol, a urea-formaldehyde aqueous syrup, the coniferous wood resin and optionally a silane and the binder composition is therefore very simple to manufacture.
The binder compositions of the invention may be "cold set" i.e. hardened at room temperature by the addition of a sulphonic acid catalyst (or hardener). Suitable sulphonic acid catalysts include para-toluene sulphonic acid, benzene sulphonic acid, cumene sulphonic acid and xylene sulphonic acid. If desired the sulphonic acid catalyst may be used in admixture with mineral acids such as phosphoric acid or sulphuric acid and mixtures thereof.
When the binder compositions of the invention are used to produce foundry moulds or cores, sand or other particulate refractory material, binder composition and a sulphonic acid catalyst are mixed together and the mixture is then formed to shape in a mould or core-box where it may be allowed to harden or set at ambient temperature.
Alternatively the binder composition may be cured by means of a catalyst such as an ammonium salt, for example ammonium chloride, ammonium nitrate or ammonium bromide and the curing being accelerated by heat. For example the so-called Hot-Box process may be used involving blowing of a mixture of sand, binder composition and catalyst into a heated corebox.
In accordance with the above the invention includes a method of making a foundry mould or core, which method comprises mixing together particulate refractory material such as sand and a binder composition according to the invention and a catalyst, forming the resulting mixture to a desired shape or shapes and causing or allowing the shape or shapes to harden.
The invention also includes a binder composition as defined above in admixture with a particulate refractory material and a sulphonic acid or ammonium salt catalyst.
The following examples will serve to illustrate the invention:
EXAMPLE 1
Binder compositions were produced as shown in the table below by blending the constituents together at ambient temperature. All percentages are by weight:
1 2 3 4 5
Furfuryl alcohol 67.9 62.9 62.9 57.9 57.9
Urea formaldehyde resin (aqueous syrup -65% solids content) 31.0 31.0 31.0 31.0 31.0
Vinsol resin - - 5.0 - 10.0
Respin resin - 5.0 - 10.0
Gamma-aminopropyltriethoxy silane 0.1 0.1 0.1 0.1 0.1 Water 1.0 1.0 1.0 1.0 1.0
The binder compositions were then tested as binders for foundry moulds and cores using the following procedure: :
5Kg of Chelford 50 silica sand was thoroughly mixed with 35g of standard commercial grade 65% para-toluene sulphonic acid. 709 of the binder composition was then added and mixing continued. The resulting mixture was used to produce standard transverse strength test cores.
The conditions under which the tests were carried out were: sand temperature 19"C ambient temperature 1 9.5'C Relative Humidity 52%
For each binder composition the "set time" (that is the time required for the binder composition to cure sufficiently for the cores to be stripped from the core box) was determined, and transverse strength measurements on cores which had been allowed to harden for various times were also made.
The following results were obtained:
Set Time Transverse Strength (kg/cm2)
Binder Composition (Minutes) after time (hours) lh 2h 3h 4h 1 30 16 42 44 48 2 29 18 36.5 46 45.5 3 28 18 31 36 40 4 29 16.5 31 35 39 5 30 16 30 34 36
EXAMPLE 2
This example demonstrates the suitability of RESPIN resin as a part replacement for furfuryl alcohol in a high furfuryl alcohol low urea-formaldehyde UF furane system.
The following binder compositions were prepared by blending the constituents together at ambient temperature. All proportions are parts by weight.
6 7 8 9
Furfuryl alcohol 78 75 73 70
U rea-formaldehyde resin (as Example 1) 5 5 5 5
Respin Resin 12 1 5 1 7 20
Silane (as Example 1) 0.15 0.15 0.15 0.15
Water 5 5 5 5
The compositions were tested using the procedure of Example 1 under the following conditions:binder 1.2% by weight of sand
PTSA catalyst 30% by weight of binder sand temperature 29"C ambient temperature 29 C Relative Humidity 80%
The following results were obtained::
Set Time Transverse Strength (kg/cm2)
Binder Composition (Minutes) after time (hours) lh 2h 3h 4h 24h 6 40 11 22.5 28 29 32.5 7 38 11 21 26 28 32
Set Time Transverse Strength (kg/cm2)
Binder Composition (Minutes) after time (hours)
1h 2h 3h 4h 24h 8 39 12 21.5 24 27 31
9 35 11.5 20 23 24 28
EXAMPLE 3
This example demonstrates the use of RESPIN resin in a low furfuryl alcohol high ureaformaldehyde UF furane system.
The following binder compositions were prepared by blending the constituents together at ambient temperature. All proportions are parts by weight.
10 11 12
Furfuryl alcohol 45 40 35
Urea-formaldehyde resin (as Example 1) 45 45 45
Respin resin 0 5 10
Silane (as Example 1) 0.15 0.15 0.15
Water 10 10 10
The compositions were tested using the procedure of Example 1 under the following conditions:binder 1.2% by weight of sand
PTSA catalyst 33.3% by weight of binder
Sand temperature 30"C ambient temperature 30 C Relative Humidity 70%
The following results were obtained:
Binder . Set Time Transverse Strength (kg/cm2)
Composition (Minutes) after time (hours) lh 2h 3h 4h 24h 10 28 7 22 24 25 27 11 25 10 22 23 25 24 12 23 8 17 20 17.5 22
EXAMPLE 4
The following binder compositions were prepared by blending the constituents together at ambient temperature. All proportions are parts by weight.
13 14 15
Furfuryl alcohol 90 80 70
Respin resin 10 20 30
Silane (as Example 1) 0.15 0.15 0.15
The compositions were tested using the procedure of Example 1 under the following conditions:binder 1.2% by weight of sand
PTSA catalyst 40% by weight of binder sand temperature 19.5"C ambient temperature 19 C Relative Humidity 52%
The following results were obtained:
Binder Set Time Transverse Strength (kg/cm2)
Composition (Minutes) after time (hours)
1h 2h 3h 24h
13 35 21 35 38 41
14 30 16.5 24 27 35
15 30 9.5 17 19 24
EXAMPLE 5
The following binder compositions were prepared by blending the constituents together. All proportions are parts by weight.
16 17 18
Furfuryl alcohol 85 75 65
Respin resin 10 20 30
Glyoxal (40% solution) 5 5 5
Silane (as Example 1) 0.15 0.15 0.15
The compositions were tested using the procedure of Example 1 under the following conditions:binder 1.2% by weight of sand
PTSA catalyst 40% by weight of binder sand temperature 19.5"C ambient temperature 1 9.5 C Relative Humidity 54%
The following results were obtained:
Binder Set Time Transverse Strength (kg/cm2)
Composition (Minutes) after time (hours) 1h 2h 3h 4h 24h
16 35 22 39 38 38 43
17 30 16 26 31 28 35.5
18 30 11 19 20 21 24.5
EXAMPLE 6
A Hot-Box resin binder composition (19) was prepared having the following composition by weight::
Furfuryl alcohol 1 5
Respin resin 5 -UF resin (as Example 1) 64
Urea 3
Water 8
Glucose 5
The binder was mixed with Chelford 50 silica sand at an addition rate of 2.0% by weight on the weight of sand and a catalyst consisting of 44% urea, 14% ammonium chloride and 42% water. The proportion of catalyst was 20% by weight based on the weight of the resin.
The resulting mixture was tested by producing tensile strength test cores in a heated core-box.
Sand was allowed to remain in the core-box for various times (dwell time). Tensile strength measurements were made on some cores 30 seconds after ejection from the core box and on some cores 30 minutes after ejection from the core box.
The conditions were as follows: ambient temperature 20 C sand temperature 20"C box temperature 230 C Relative Humidity 50%
The following results were obtained:
Dwell Time Tensile Strength (kg/cm2) (Seconds) After 30 seconds After 30 mins.
10 2.7 21 20 5.1 20 30 6.2 32 40 8 35 50 11 29 60 14 28
EXAMPLE 7
The following binder compositions were prepared. All proportions are parts by weight:
20 21 22 23
Furfuryl alcohol 55 49.5 46.75 44.0
Phenol-formaldehyde resol resin (formaldehyde: phenol 3:1) 45 40.5 38.25 36.0
Respin resin 10 1 5 20
Silane (as Example 1) 0.15 0.15 0.15 0.15
The compositions were tested using the procedure of Example 1 under the following conditions:binder 1.2% by weight of sand
PTSA catalyst 40% by weight of binder sand temperature 20.2 C ambient temperature 20"C Relative Humidity 58%
The following results were obtained: :
Binder Set Time Transverse Strength (kg/cm2)
Composition (Minutes) after time (hours)
1h 2h 3h 4h 24h 20 28 12 19 19 24 26.5 21 28 12.5 16 20 22 26 22 27 12.5 19 22 20 25 23 26 11 19.5 19.5 21.5 27
Claims (18)
1. A binder composition comprising furfuryl alcohol and a resin produced from coniferous wood and soluble in furfuryl alcohol.
2. A binder composition according to claim 1 wherein the resin is produced from the oleoresinous constituents of southern pinewood.
3. A binder composition according to claim 1 wherein the resin is produced from the wood of Araucaria Angustifolia.
4. A binder composition according to any of claims 1 to 3 which also includes glyoxal or formaldehyde.
5. A binder composition according to any of claims 1 to 4 which also includes urea formaldehyde resin or precondensate and/or phenol-formaldehyde resole resin.
6. A binder composition according to any of claims 1 go 5 which also contains a diluent liquid.
7. A binder composition according to any of claims 1 to 6 which contains by weight:
Furfuryl alcohol 15-95%
Coniferous wood resin 5-30% Phenoi-formaldehyde resole resin 0-60%
Urea-formaldehyde resin or precondensate 0-70%
Glyoxal or formaldehyde 0-20%
Diluent liquid 0-35%
8. A binder composition according to claim 7 which contains by weight:
Furfuryl alcohol 70-95%
Coniferous wood resin 5-30%
Diluent liquid 0-10%
9. A binder composition according to claim 7 which contains by weight:
Furfuryl alcohol 50-90%
Coniferous wood resin 5-30%
Glyoxal or formaldehyde 5-20%
Diluent liquid 0-10%
10.A binder composition according to claim 7 which contains by weight:
Furfuryl alcohol 15-90% Coniferous wood resin 5-30% Phenol-formaid;hyde resole resin 0-60%
Urea-formaldehyde resin or precondensate 0-70%
Diluent liquid 0-30%
11. A binder composition according to any of claims 1 to 10 which includes a silane.
1 2. A binder composition according to any one of the preceding claims in admixture with a sulphonic acid catalyst or an ammonium salt catalyst and a particulate refractory material.
1 3. A binder composition according to claim 1 as hereinbefore described in any one of the specific Examples.
1 4. A method of making a foundry mould or core which method comprises mixing together a particulate refractory material, a binder composition according to any one of claims 1 to 1 2 and a catalyst, forming the resulting mixture to a desired shape and causing or allowing the shape to harden.
1 5. A method according to claim 1 4 wherein the catalyst is a sulphonic acid and the mixture is allowed to harden at room temperature.
16. A method according to claim 14 wherein the catalyst is an ammonium salt and the mixture is hardened in a heated core-box.
1 7. A method according to any of claims 14 to 1 6 substantially as hereinbefore described with reference to any one of the specific Examples.
18. A foundry mould or core when made by a method according to any of claims 14 to 17.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB8126662A GB2085453B (en) | 1980-10-17 | 1981-09-03 | Furfuryl alcohol resin-wood resin binder compositions |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB8033602 | 1980-10-17 | ||
| GB8126662A GB2085453B (en) | 1980-10-17 | 1981-09-03 | Furfuryl alcohol resin-wood resin binder compositions |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| GB2085453A true GB2085453A (en) | 1982-04-28 |
| GB2085453B GB2085453B (en) | 1984-03-07 |
Family
ID=26277252
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB8126662A Expired GB2085453B (en) | 1980-10-17 | 1981-09-03 | Furfuryl alcohol resin-wood resin binder compositions |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB2085453B (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103289037A (en) * | 2013-04-01 | 2013-09-11 | 黄石市汇波防腐技术有限公司 | Furan resin having a low formaldehyde content and good collapsibility used for casting |
-
1981
- 1981-09-03 GB GB8126662A patent/GB2085453B/en not_active Expired
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103289037A (en) * | 2013-04-01 | 2013-09-11 | 黄石市汇波防腐技术有限公司 | Furan resin having a low formaldehyde content and good collapsibility used for casting |
| CN103289037B (en) * | 2013-04-01 | 2015-04-29 | 黄石汇波材料科技股份有限公司 | Furan resin having a low formaldehyde content and good collapsibility used for casting |
Also Published As
| Publication number | Publication date |
|---|---|
| GB2085453B (en) | 1984-03-07 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| 732 | Registration of transactions, instruments or events in the register (sect. 32/1977) | ||
| PCNP | Patent ceased through non-payment of renewal fee |