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Accelerated furanic aggregate binders from bio-derived components

a technology of furanic aggregate and binders, which is applied in the field of bioderived binder materials, can solve the problems of corrosive action, waste removal, health, and each of these components can have negative effects on the environment, so as to reduce any environmental impact and improve the overall performan

Inactive Publication Date: 2008-05-29
BATTELLE MEMORIAL INST
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0033]Advantages of the present invention are the replacement of petrochemical-based materials in some metal casting applications, partial replacement of furfuryl alcohol in furanic acid-cured type binders, replacement of reacted base resins, very fast cure response, elimination of formaldehyde and urea from the process, reduced cost in binder manufacturing time, reduction or removal of formaldehyde or phenol, reduction in the amounts and / or type of acid catalyst used, and formulations of making metal casting binders that may include the exclusive use of a inorganic acid catalyst while utilizing a cold-blended resin composite.

Problems solved by technology

Each of these components can have negative effects in terms of environment, health, waste removal (spent sand disposal), core / mold-making or casting performance.
The problems with sulfur containing catalysts are the release of potentially harmful aromatic species into the work environment (EP 1531018), corrosive action on the pattern and related tooling, corrosion of catalyst storage tanks or transfer pipes and valves, handling safety, and sulfur contamination of sensitive metal alloys (Gieniec).
Cold-box processes are highly productive, but require the use of highly specialized equipment, and in the case of furanic cold-box processes, can be highly corrosive to foundry equipment.

Method used

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  • Accelerated furanic aggregate binders from bio-derived components

Examples

Experimental program
Comparison scheme
Effect test

example 1

[0062]Example 1 illustrates the use of FDM in a furanic a cid-cured binder formulation.

[0063]Table 1 shows formulations with FDM as a binder element.

TABLE 1FDM as an Additive in a Furanic No Bake (FNB) BinderTest No.IngredientsControl123456Furfuryl Alcohol96.091.086.076.066.069.856.0(pph*)Resorcinol3.853.853.853.853.8503.85(pph*)Silane**0.150.150.150.150.150.150.15(pph*)FDM05.010.020.030.03040.0(pph*)*pph = parts per hundred (weight)

[0064]Table 1 lists six formulations and a control for FDM as an additive in an FNB binder. The ingredients in each of the formulations were added to an 8 oz jar and shaken until dissolved to a clear amber solution.

[0065]The catalyst solution was comprised of 38 (weight percent) wt % Columbus, Ohio tap water, 2 wt % methanol, and 60 wt % para-toluene sulfonic acid (Aldrich).

[0066]To 4000 grams of Wedron 540® sand (Fairmont Minerals), 20 grams (40% on binder weight) of this aromatic sulfonic acid catalyst solution was added and mixed for one minute in a H...

example 2

The Use of Phosphoric Acid

[0071]This example illustrates the use of phosphoric acid instead of para-toluene sulfonic acid. The use of phosphoric acid is advantageous for those alloys negatively impacted by sulfur contamination and by the elimination of benzene-like molecules into the work environment after pouring the metal. Typically, phosphoric acid is not acceptable for use with “cold-blended” furan binder systems due the slow reactivity and lack of tensile development, especially on colder aggregates. The Control was run at 50% of 85% phosphoric based on binder weight. The test formulations were tested at 50 and 40% of phosphoric acid as shown on Table 3. The Table 3 series also shows the tests for several typical polyester fillers in combination with the FDM.

[0072]The formulations on Table 3 were made in the laboratory as described and tested in example one, except for the use of two different levels of the catalyst.

TABLE 3FDM-containing FNB Binder FormulationsCured with 85% Ph...

example 3

[0075]This example illustrates FDM formulation performance on warm and cold aggregates.

[0076]The performance of furan no-bake binders can be severely affected by the temperature of the aggregates as well as ambient temperatures and humidity. A faster curing binder formulation should perform better on cold sands. Ideally, such a binder formulation should still perform acceptably on warm sand as well. A typical-means of achieving fast cure on cold sand is the use of reacted base formulations, the reacted base being, for example, a urea-formaldehyde resin. Such resins increase the reactivity, but also introduce free formaldehyde into the formulations. Another means of achieving faster cure on cold sands is to use either higher levels of an acid catalyst, use a higher reactivity sulfonic acid, or one containing an inorganic acid “kicker”, such as straight sulfuric acid or hydrochloric acid. Other means of increasing reactivity on cold sands include the addition of alcohols, such as meth...

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PUM

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Abstract

Broadly, the invention provides for newly available bio-derived formaldehyde-free furanic materials for aggregate binding. A specific example is aggregate binding for forms used in the metal casting process. The inventive binder formulations involve the use of 2,5-furan dimethanol and other “filler” components for high productivity and fast tensile development without formaldehyde, urea, urea-formaldehyde or formaldehyde containing compositions.

Description

[0001]This application claims the benefits of U.S. Provisional Application 60 / 848,329, filed Sep. 29, 2006. The entire disclosure of the provisional application is incorporated herein by reference.FIELD OF THE INVENTION[0002]The present invention provides bio-derived binder materials as a partial replacement or addition to furfuryl alcohol along with a synergistic “filler” material for use in applications such as acid-cured aggregate binders like those used in the metal casting industry for making self-hardenable forms for shaping cast metal parts. These forms are made by coating an aggregate (for example, sand) with a binder comprising an add-curable resin and an add-based curing agent, charging the mixture into a pattern, and allowing the binder to cure. This invention includes components and formulation compositions typically based on plant-derived materials as binder components. In the Furan No-Bake process, the aggregate is coated sequentially by the acid catalyst, then the aci...

Claims

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Application Information

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IPC IPC(8): B22C1/22B22C1/20
CPCB22C1/224
Inventor CLINGERMAN, MICHAEL C.KAWCZAK, ALEX W.SCHNEIDER, JAMES T.
Owner BATTELLE MEMORIAL INST
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