Furanic resin aggregate binders and method

a technology of furfuryl alcohol and aggregate, which is applied in the field of plant-based compositions, can solve the problems of petrochemically-derived materials that need to be replaced with bio-derived materials, the supply of furfuryl alcohol is likely to become more restricted, and the supply of furfuryl alcohol is likely to increase. , to achieve the effect of improving the performance of acid cured binder, and boosting the strength of metal casting

Inactive Publication Date: 2008-08-28
BATTELLE MEMORIAL INST
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0014]Efforts have also been made to find alternative resins to improve acid cured binder performance. U.S. Pat. No. 6,559,203, for example discusses the use of alternative resorcinol resins to boost metal casting form strength. The inventive formulations boost metal casting strengths with minimal use of resorcinol.

Problems solved by technology

Briefly, there is an increasing need to replace petrochemically-derived materials with bio-derived materials due to the gradual decrease in the world supply of petrochemical supplies and the rising costs associated with this decline.
However, furfuryl alcohol is typically an imported raw material in North America and therefore subject to trade and economic issues.
In the near future, the furfuryl alcohol supply is likely to become more restricted as the world economy grows and the overseas use of furfuryl alcohol increases.

Method used

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  • Furanic resin aggregate binders and method
  • Furanic resin aggregate binders and method

Examples

Experimental program
Comparison scheme
Effect test

example 1

[0064]This example illustrates the use of 5-hydroxymethyl furfural in a furanic acid-cured binder formulation. Table 1 shows formulations with 5-hydroxymethyl furfural as a binder element.

TABLE 1Formulations with HMF binderTest NumberControl123Furfuryl Alcohol96.091.086.076.0(pph1)Resorcinol3.853.853.853.85(pph1)Silane20.150.150.150.15(pph1)5-hydroxymethyl05.010.020.0furfural (pph1)1pph = parts per hundred (weight)23-(diethoxymethylsilyl) propylamine

[0065]The ingredients in each of the Table 1 formulations were added to an 8 oz jar and shaken until dissolved to a clear amber solution.

[0066]The catalyst solution was comprised of 38% tap water, 2% methanol, and 60% para-toluene sulfonic acid (Aldrich).

[0067]To 4000 grams of Wedron 540™ sand, 20 grams of an aromatic sulfonic acid catalyst solution was added and mixed for one minute in a Hobart N50 mixer. This aggregate mixture then was manually flipped and mixed for another minute. Each formulation (50 grams) was added to the aggregate...

example 2

[0072]This example illustrates the use of 2,5-furan dimethylol as a filler and replacement for a portion of the furfuryl alcohol in furanic acid-cured binder formulations. Table 3 shows formulations utilizing 2,5-furan dimethylol in furanic acid-cured binder formulations. The acid in this case is the standard p-toluene sulfonic acid described in Example 1. The Example illustrates that the 2,5-furan dimethylol can be used as an accelerator / filler despite the absence of added free formaldehyde.

TABLE 3Test No.Control12345Furfuryl Alcohol96.091.086.076.066.056.0(pph1)Resorcinol23.853.853.853.853.853.85(pph1)Silane30.150.150.150.150.150.15(pph1)2,5-Furan Dimethylol05.010.020.030.040.0(pph1)1pph = parts per hundred (weight)2Resorcinol, 98% (Sigma-Aldrich)33-(diethoxymethylsilyl) propylamine (Aldrich)

[0073]Each Table 3 formula was compounded and tested as in Example 1, the test results are shown in Table 4.

TABLE 4TestControl12345Work time (minutes)292222191512Strip time (minutes)4538332519...

example 3

[0077]This example illustrates the use of 2,5-furan dimethylol as a component of a filler package and replacement for a portion of the furfuryl alcohol in furanic acid-cured binder formulations using weak acid catalyst. Table 5 shows formulations utilizing 2,5-furan dimethylol in furanic acid-cured binder formulations. The acid is 85% phosphoric at 50% based upon resin. The Example illustrates that the 2,5-furan dimethylol can be used as an accelerator / filler despite the absence of added free formaldehyde and even with a weak acid catalyst. Table 5 shows 2,5-furan dimethylol in various combinations of typical furanic additives at up to 30% replacement of furfuryl alcohol.

TABLE 5TestControl123Furfuryl Alcohol96.078.568.569.85(pph1)Resorcinol23.853.853.850.0(pph1)Silane30.150.150.150.15(pph1)Phenrez 17807.57.502,5-Furan Dimethylol010.020.030.0(pph1)1pph = parts per hundred (weight)2Resorcinol, 98% (Sigma-Aldrich)33-(diethoxymethylsilyl) propylamine (Aldrich)

[0078]Each Table 3 formula ...

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Abstract

Broadly, the invention provides for newly available bio-derived formaldehyde free furanic materials for aggregate binding. The specific example case is aggregate binding for forms used in the metal casting process. The new materials make possible higher productivity and lower phenol, formaldehyde, urea, and/or furfuryl alcohol content in the metal casting form-making process. It is expected that the formulations will work well in other aggregate binding situations as well.

Description

[0001]This application claims the benefits of U.S. Provisional Application No. 60 / 848,279, filed Sep. 29, 2006. The entire disclosure of the provisional application is incorporated by reference herein.FIELD OF THE INVENTION[0002]The present invention provides plant-based compositions for use as binder materials in applications such as acid-cured aggregate binders. Such compositions can be used in a range of composites, adhesives, coatings and other applications. For example, such compositions are used in the metal casting industry for making self-hardenable forms for shaping cast metal parts. These forms are composites of aggregate (for example, sand) with an acidic curing agent and an acid-curable composition. In the Furan No-Bake process, the aggregate is coated sequentially by the added catalyst, then the add hardenable composition, and the mixture is then charged into a pattern. The composition then cures over a period of time at ambient conditions and the hardened forms are rem...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): B22C1/22
CPCB22C1/2253B22C1/2266C08L61/04C08G18/542C08G8/06
Inventor CLINGERMAN, MICHAEL C.KAWCZAK, ALEX W.SCHNEIDER, JAMES T.
Owner BATTELLE MEMORIAL INST
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