Foundry Mold Binder Composition with Amine Phosphate Against Thickening
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Solution Overview
Problem
Existing binder compositions for foundry molds face issues with thickening in high-temperature environments, particularly when furfuryl alcohol content is reduced, leading to storage stability problems and handleability challenges, and the formation of insoluble salts that can clog supply devices.
Innovation Solution
A binder composition containing furfuryl alcohol, furan resin, water, and amine phosphate is formulated to suppress thickening and precipitation, using phosphoric acid as an acid catalyst and maintaining specific content ranges to ensure stability and solubility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the content of furfuryl alcohol is reduced to lower environmental hazards, then the amount of volatilized furfuryl alcohol and formaldehyde decreases, but the binder composition undergoes thickening during storage due to condensation reaction of oligomer components
Solution Approach 1:
A metal hydroxide (such as calcium hydroxide, magnesium hydroxide, or aluminum hydroxide) is introduced as an intermediary substance to neutralize the acid catalyst residual in the furan resin. This mediator prevents further condensation reactions during storage that would cause thickening, while allowing the binder composition to maintain low furfuryl alcohol content for reduced environmental hazards.
Solution Approach 2:
The pH parameter of the binder composition is adjusted by adding metal hydroxide to neutralize acidic components. This parameter change stops the condensation reaction progression during storage, preventing molecular weight increase and thickening, while maintaining the low furfuryl alcohol content formulation.
2Stability of the object's composition
If a metal hydroxide is added to suppress thickening, then storage stability improves, but insoluble salts may form and clog supply devices
Solution Approach 1:
The pH parameter is precisely controlled within a specific range (pH 6-9) by adjusting the amount of metal hydroxide added. This parameter optimization ensures sufficient neutralization to prevent thickening while maintaining solubility of phosphate salts to avoid clogging supply devices.
Solution Approach 2:
A composite system is created combining furan resin, metal hydroxide, and phosphate in specific proportions. This composite formulation achieves both thickening suppression through neutralization and prevention of insoluble salt precipitation, resolving the contradiction between storage stability and supply device operability.
3Object-affected harmful factors
If the content of furfuryl alcohol is reduced, then environmental hazards are lowered, but the binder composition requires additional components to prevent thickening, increasing formulation complexity
Solution Approach 1:
The metal hydroxide serves multiple functions simultaneously: it neutralizes the acid catalyst to prevent thickening, adjusts the pH to maintain stability, and prevents formation of insoluble salts when used in controlled amounts. This multi-functionality reduces the need for multiple separate additives, simplifying the overall formulation despite the reduced furfuryl alcohol content.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composition effectively prevents thickening and precipitation, improving handleability and reducing environmental hazards while maintaining mold strength and production efficiency.
Implementation Method 1
the binder composition contains a large amount of an oligomer component such as a urea-modified furan resin instead of the reduced furfuryl alcohol and thus a condensation reaction proceeds during storage to increase the molecular weight
Implementation Method 2
defects may be caused in a supply device and piping at the time of producing a foundry mold due to precipitation of an insoluble salt
Implementation Method 3
A urea-modified furan resin, a furfuryl alcohol/formaldehyde condensate, or the like, which is a main component of a furan resin, is obtained by reacting furfuryl alcohol with urea or formaldehyde in the presence of an acid catalyst
Data Source
AI summary
The present invention is a binder composition for making foundry molds, the binder composition including: furfuryl alcohol; a furan resin; water; and a phosphate, the binder composition satisfying Conditions (1) to (4) described below: Condition (1): the binder composition has a content of furfuryl alcohol of more than 0 mass% and 30 mass% or less, Condition (2): the binder composition has a content of the furan resin of 20 mass% or more and 60 mass% or less, Condition (3): the binder composition has a content of water of 5 mass% or more and 30 mass% or less, and Condition (4): the phosphate includes an amine phosphate. According to the present invention, it is possible to provide a binder composition for making foundry molds that contains a furan resin produced using phosphoric acid as an acid catalyst, has a small content of furfuryl alcohol, and is capable of suppressing precipitation of an insoluble phosphate while suppressing thickening at the time of storage of the binder composition for making foundry molds.