EP3478429A1 - Composition alcaline aqueuse de liant, à durcir avec du dioxyde de carbone, son utilisation, mélange de matières à mouler correspondant pour la fabrication d'un corps de moule de fonderie, corps de moule de fonderie correspondant et procédé de fabrication d'un corps moule de fonderie - Google Patents

Composition alcaline aqueuse de liant, à durcir avec du dioxyde de carbone, son utilisation, mélange de matières à mouler correspondant pour la fabrication d'un corps de moule de fonderie, corps de moule de fonderie correspondant et procédé de fabrication d'un corps moule de fonderie

Info

Publication number
EP3478429A1
EP3478429A1 EP17736600.2A EP17736600A EP3478429A1 EP 3478429 A1 EP3478429 A1 EP 3478429A1 EP 17736600 A EP17736600 A EP 17736600A EP 3478429 A1 EP3478429 A1 EP 3478429A1
Authority
EP
European Patent Office
Prior art keywords
binder composition
range
phenol
aqueous alkaline
mol
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.)
Withdrawn
Application number
EP17736600.2A
Other languages
German (de)
English (en)
Inventor
Gérard LADÉGOURDIE
Nicolas Egeler
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Huettenes Albertus Chemische Werke GmbH
Original Assignee
Huettenes Albertus Chemische Werke GmbH
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Huettenes Albertus Chemische Werke GmbH filed Critical Huettenes Albertus Chemische Werke GmbH
Publication of EP3478429A1 publication Critical patent/EP3478429A1/fr
Withdrawn legal-status Critical Current

Links

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
    • B22C1/167—Mixtures of inorganic and organic binding agents
    • 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
    • B22C1/162—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 use of a gaseous treating agent for hardening the binder
    • 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
    • B22C1/18—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 inorganic agents
    • B22C1/186—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 inorganic agents contaming ammonium or metal silicates, silica sols
    • B22C1/188—Alkali metal silicates
    • 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
    • B22C1/2246—Condensation polymers of aldehydes and ketones
    • B22C1/2253—Condensation polymers of aldehydes and ketones with phenols
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/12—Treating moulds or cores, e.g. drying, hardening
    • B22C9/123—Gas-hardening
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/38—Boron-containing compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/54—Silicon-containing compounds
    • C08K5/541—Silicon-containing compounds containing oxygen
    • C08K5/5435—Silicon-containing compounds containing oxygen containing oxygen in a ring
    • 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
    • C08L61/04—Condensation polymers of aldehydes or ketones with phenols only
    • C08L61/06—Condensation polymers of aldehydes or ketones with phenols only of aldehydes with phenols
    • 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
    • C08L61/04—Condensation polymers of aldehydes or ketones with phenols only
    • C08L61/06—Condensation polymers of aldehydes or ketones with phenols only of aldehydes with phenols
    • C08L61/14—Modified phenol-aldehyde condensates
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/38—Boron-containing compounds
    • C08K2003/387—Borates

Definitions

  • the present invention relates to an aqueous alkaline binder composition for curing with carbon dioxide gas, the use of the aqueous alkaline binder composition, a molding material mixture for producing a foundry molding and a corresponding method for producing a foundry molding and a corresponding foundry molding.
  • foundry moldings there are three main types of foundry moldings in the foundry industry. Cores and molds are foundry moldings, which usually represent in combination with each other the negative mold of a casting to be produced. Feeder elements form hollow bodies, which serve as a compensation reservoir to avoid voids formation. These foundry molded bodies regularly comprise a molding base material, for example quartz sand or another refractory material, or a corresponding molding material. Substance mixture and a suitable binder that gives the foundry molding after removal from the mold sufficient mechanical strength. A molding material mixture is usually and preferably present in a free-flowing form, so that it can be filled into a suitable mold and compacted there. By adding the binder, a firm cohesion between the particles of the mold base material is produced, so that the resulting foundry molded body receives the required mechanical stability. The foundry moldings themselves must meet various requirements, such as a sufficiently high strength.
  • EP 0 363 385 B1 relates to "modifier for aqueous basic solutions of phenolic resins" (title).
  • WO 03/016400 A1 relates to a "C0 2 -hardenable binder system based on resole" (designation).
  • EP 0 323 096 B1 relates to the "Production of articles of bonded particulate material and binder compositions for use therein” (title).
  • WO 97/18913 relates to a "cold-box process for preparing foundry shapes" (title).
  • No. 5,242,957 A relates to "alkaline resol phenol-aldehyde resin binder compositions containing phenyl ethylene glycol ether" (title).
  • WO 01/12709 A1 relates to an "aluminum and boron-containing binder system based on resole" (title).
  • EP 2 052 798 A1 relates to "alkaline resol phenol-aldehyde resin binder compositions" (title).
  • EP 0 503 758 B1 relates to a "binder of alkaline phenol-aldehyde resole resins" (title).
  • US 4,977,209 A relates to the "Production of articles of bonded particulate material and binder compositions for use therein of phenol-formaldehyde and oxyanion” (title).
  • GB 2 253 627 A relates to "alkaline resol phenol-aldehyde resin binder compositions" (title).
  • EP 2 052 798 B1 relates to a "binder composition of alkaline phenolaldehyde resole resins" (title).
  • EP 0 508 566 B1 relates to "alkaline resol phenol-aldehyde resin binder compositions" (title).
  • EP 0 503 759 B1 relates to "alkaline resol phenol-aldehyde resin binder compositions" (title).
  • EP 0 556 955 B1 relates to an "alkaline resole phenol-aldehyde-resin binder" (title).
  • one or more other tasks should be solved:
  • an aqueous alkaline binder composition for curing with carbon dioxide gas can be produced with the foundry moldings, which compares particularly high strength both after a short storage time (for example, after 1 hour) after long storage periods (of 24 hours or longer, even at high humidities) under normal storage conditions.
  • a particularly high strength should preferably be retained even after the finishing with conventional water-based finishes.
  • an object of the present invention to provide an aqueous alkaline binder composition for curing with carbon dioxide gas, which has a particularly high, preferably increased flowability compared to the binder compositions known from the prior art.
  • an object of the present invention to provide an aqueous alkaline binder composition for curing with carbon dioxide gas, which can be used to produce foundry moldings, which compared to the known from the prior art foundry moldings improved surface finish and / or improved Have edge hardness.
  • an aqueous alkaline binder composition for curing with carbon dioxide gas can be produced with the foundry moldings with a particularly high, preferably higher initial strength compared to the binder compositions known in the art.
  • an aqueous alkaline binder composition for curing with carbon dioxide gas comprising
  • a phenol group-containing, negatively charged or uncharged phenol-aldehyde resin selected from the group consisting of resoles and mixtures comprising one or more resoles and one or more novolacs, an oxyanion selected from the group consisting of borate ions, aluminas, stannate Ions, zirconate ions, titanate ions and mixtures thereof to form a stable complex with the resol-phenolaldehyde resin,
  • the molar total amount of the phenol groups of the phenol-aldehyde resin in the aqueous alkaline binder composition is in the range of 1 to 3 mol / kg based on the total mass of the aqueous alkaline binder composition and
  • phenol-aldehyde resin has an average molecular weight (Mw) in the range of 750 to 1200 g / mol as determined by gel permeation chromatography. For the method of determination, see below.
  • the average molecular weight (Mw) of the phenol-aldehyde resin used according to the invention is exceptionally high in the binder composition according to the invention.
  • aqueous alkaline binder compositions according to the invention at least one resole (negatively charged or uncharged) is present in each case, one or more novolacs (negatively charged or uncharged) may additionally be present.
  • Negatively charged resole or negatively charged novolak is present in particular when phenol groups are present in phenolate form.
  • Novolacs are soluble, meltable, non-self-curing and storage-stable phenolic oligomers. They are obtained in the acid-catalyzed condensation of aldehyde and phenol in a molar ratio of 1:> 1. Novolacs are phenol resins free from methylol groups, in which the phenolic groups (also called phenyl nuclei) are bridged. For the definition of phenolic groups or phenyl nuclei, see below.
  • Resoles are mixtures of hydroxymethylphenols linked via methylene and methylene ether bridges and obtainable by alkaline catalyzed or divalent metal ions such as Zn 2+ catalyzed reaction of aldehyde and phenols in a molar ratio of 1: ⁇ 1.
  • Preferred (uncharged) phenol-aldehyde resins for use in binder compositions of the present invention are condensation products of
  • A, B and C independently of one another ie a substituent A is for example independently of the substituent B and the substituent C defined as well as independent of the substituents A of another phenol of the formula I defined
  • hydrogen unsaturated or saturated aliphatic groups not more than 16 carbon atoms
  • the aliphatic groups are preferably alkyl groups, which are preferably selected from the group consisting of methyl, ethyl, n-propyl, / propyl, n-butyl, / -butyl, ieri-butyl, octyl and Nonyl, or olefinic groups
  • R ' is a hydrogen atom or an alkyl group having an alkyl main chain length of 1-8 carbon atoms.
  • phenols which fall under the formula I are phenol (C 6 H 5 OH), o-cresol, m-cresol, p-cresol, p-butylphenol, p-octylphenol, p-nonylphenol and cardanol (name for compounds of formula I, wherein B is an aliphatic, unbranched group of 15 C atoms and 0, 1, 2 or 3 double bonds); Of these, phenol (C 6 H 5 OH), o-cresol and cardanol are preferred, phenol (C 6 H 5 OH) is particularly preferred.
  • aldehyde formaldehyde is regularly preferred, which can also be used in the form of para-formaldehyde. Particular preference is given in practice to (i) formal dehyde used as the sole aldehyde or (ii) formaldehyde used in combination with one or more other aldehydes.
  • the or a phenol-aldehyde resin used according to the invention comprises a resin in which the phenyl nuclei are linked via ortho-para or para-para methylene bridges, cf. EP 2052798 A1.
  • this or the phenolic aldehyde resin used in the present invention comprises an ortho-fused phenolic resole, i. H. a phenol resin of the benzyl ether resin type.
  • the above information on preferred phenols and aldehydes and the resulting preferred phenol-aldehyde resins also apply to the binder composition according to the invention, which is described in detail below.
  • the present invention preferably relates to such phenol-aldehyde resins, for the production of which formaldehyde is used.
  • Uncharged phenol-aldehyde resins can be converted to corresponding negatively charged phenol-aldehyde resins in the presence of strong bases, with the release of protons.
  • the above statements on preferred uncharged phenol-aldehyde resins apply mutatis mutandis to the negatively charged phenol-aldehyde resins.
  • aqueous alkaline binder composition are preferably present negatively charged phenol-aldehyde resins, optionally in admixture with uncharged phenol-aldehyde resin.
  • a negatively charged or uncharged phenol-aldehyde resin comprises phenolic oligomers or phenolic polymers (see above) which contain, inter alia, phenol groups or phenyl nuclei.
  • a phenol group or a phenyl nucleus in the context of the present invention is a structural molecular unit of the phenol-aldehyde resin, which contains exactly one aromatic, according to the Hückel rule conjugated ring system with 6 delocalized electrons.
  • Formula VII shows schematically such a molecular unit, wherein R1 to R6 do not belong to the phenol group or to the phenyl nucleus, but represent substituents on the phenol group or on the phenyl nucleus.
  • Oxyanions are preferably compounds in the context of the present invention.
  • M is selected from the group consisting of B, Al, Sn, Zr and Ti and
  • Borate ions and aluminate ions are preferred oxyanions for use in binder compositions of this invention, particularly preferred are combinations of borate and aluminate.
  • a binder composition of the invention for curing with carbon dioxide gas (as defined above) is preferred, comprising
  • a phenol group-containing, negatively charged or uncharged phenol-aldehyde resin selected from the group consisting of resoles and mixtures comprising one or more resoles and one or more novolacs, an oxyanion selected from the group consisting of aluminate ions, stannate ions, zirconate Ions, titanate ions and mixtures thereof, to form a stable complex with the resol-phenolaldehyde resin,
  • the total molar amount of the phenol groups of the phenol-aldehyde resin in the aqueous alkaline binder composition is in the range of 1 to 3 mol / kg based on the total mass of the aqueous alkaline binder composition
  • phenol-aldehyde resin has an average molecular weight (Mw) in the range from 750 to 1200 g / mol, determined by means of gel permeation chromatography,
  • the binder composition preferably contains less than 1 wt .-% borate ions, preferably less than 0, 1 wt .-%, more preferably less than 0.05 wt .-%, each based on the total mass of the aqueous alkaline binder composition, and most preferably contains no borate ions.
  • binder compositions according to the invention comprising a phenol-aldehyde resin having an abovementioned average molecular weight (M w) lead to a particularly high flexural strength of the resulting foundry moldings after a storage time of 24 hours and after 5 days under normal storage conditions and after finishing the foundry moldings ,
  • normal storage conditions are 20 ° C (+/- 2 ° C), atmospheric pressure, and a relative humidity of 47% (+/- 2%).
  • binder compositions according to the invention which comprise a phenol-aldehyde resin having an average molecular weight (Mw) in the abovementioned range lead to a particularly high strength of the resulting foundry moldings after a storage time of 15 seconds (ie "initial strength") under normal storage conditions; see below for preferred average molecular weights of the phenol-aldehyde resin, which makes it possible to produce particularly filigree foundry moldings.
  • the own foundry moldings have proven to be particularly resistant to humidity and can therefore be stored for a long time even without the exclusion of air.
  • binder composition according to the invention (as defined above, preferably as defined above as preferred), wherein
  • the phenol-aldehyde resin has an average molecular weight (Mw) in the range from 750 to 1000 g / mol, preferably in the range from 780 to 980 g / mol and more preferably in the range from 850 to 980 g / mol, determined by gel permeation chromatography.
  • Mw average molecular weight
  • binder compositions of the invention comprising a phenol-aldehyde resin having a preferred average molecular weight (Mw) mentioned above to a very high flexural strength of the resulting foundry moldings after a storage time of 24 hours and after 5 days under normal storage conditions and after the sizing of Lead foundry body.
  • Mw preferred average molecular weight
  • binder compositions of the present invention which comprise a phenol-aldehyde resin having an average molecular weight (Mw) in the above-mentioned particularly preferred range, result in a particularly high flexural strength of the resulting foundry moldings after a shelf life of 15 seconds (ie, "initial strength") under normal storage conditions
  • the resulting foundry moldings have proven to be particularly resistant to humidity in their own tests and can therefore be stored for a long time even without the exclusion of air.
  • binder composition according to the invention (as defined above, preferably as defined above as preferred), additionally comprising
  • one or more silanes in a total amount in the range of 0.5 to 1 1 wt .-%, preferably in the range of 2.5 to 10 wt .-%, particularly preferably in the range of 3.0 to 10 wt .-%, most preferably in the range of 3.5 to 7 wt .-%, particularly particularly preferably in the range of 3.5 to 6 wt .-%, based on the total mass of the binder composition.
  • binder compositions according to the invention which comprise silanes in an (exceptionally high) total amount in the range from 0.5 to 1% by weight or in the range from 2.5 to 10% by weight, based on the total mass of the binder composition, lead to particularly or very particularly solid and therefore also particularly stable or very stable stable foundry moldings.
  • the resulting foundry moldings have proven to be particularly resistant to humidity; They are therefore long storable even without exclusion of air.
  • binder compositions according to the invention comprising the abovementioned preferred total amounts of one or more silanes lead to a particularly high strength of the resulting foundry moldings after a storage time of 24 hours under normal storage conditions. Presumably it comes in the presence of
  • one or more silanes in a total amount in the range of 0.5 to 1 1 wt .-% and in the range of 2.5 to 10 wt .-%, based on the total mass of the binder composition,
  • a phenol-aldehyde resin having an average molecular weight (Mw) in the range from 750 to 1200 g / mol, preferably in the range from 750 to 900 g / mol and especially preferably in the range from 750 to 800 g / mol, determined by means of gel permeation chromatography,
  • Compounds of formula VIII are preferred silanes for use in an aqueous alkaline binder composition of the invention.
  • R, R 2 , R 3 and R 4 are independently (ie a substituent R is, for example, independently of the substituent R 2 , the substituent R 3 and the substituent R 4 defined) hydrogen, unsaturated or saturated aliphatic or aromatic groups with or without substituents; preferred substituents are oxygen, chlorine, nitrogen, sulfur, fluorine, bromine or iodine atoms.
  • Epoxysilanes are particularly preferred silanes for use in an aqueous alkaline binder composition of the invention; Epoxysilanes are compounds of formula VIII above in which one or more of the substituents R, R 2 , R 3 and R 4 has at least one epoxy moiety.
  • An epoxy unit is a three-membered ring in which a carbon atom is replaced by an oxygen atom in comparison to the cyclopropane.
  • R, R 2 , R 3 and R 4 are independently selected from the group consisting of
  • R, R 2 , R 3 and R 4 are independently selected from the group consisting of
  • Glycidyloxyalkyl i.e., 3- (2,3-epoxypropoxy) alkyl.
  • Each of the substituents R, R 2 , R 3 and R 4 defined above preferably has a total number of carbon atoms in the range from 1 to 20, particularly preferably in the range from 1 to 10, very particularly preferably in the range from 1 to 6.
  • R, R 2 , R 3 and R 4 are independently selected from the group consisting of
  • 3-Glycidyloxypropyl ie, 3- (2,3-epoxypropoxy) propyl.
  • a binder composition according to the invention (as defined above, preferably as defined above as being preferred),
  • silanes used are selected from the group consisting of 3-aminopropyltriethoxysilane, N- (2-aminoethyl) -3-aminopropyltrimethoxysilane and phenyltrimethoxysilane and / or are selected from the group of epoxysilanes,
  • silanes used are preferably selected from the group consisting of 3- (glycidyloxy) propyl-triethoxysilane and 3- (glycidyloxy) propyltrimethoxysilane.
  • a binder composition according to the invention preferably comprises only silanes which are selected from the group consisting of 3-aminopropyltriethoxysilane, N- (2-aminoethyl) -3-aminopropyltrimethoxysilane and phenyltrimethoxysilane and / or are selected from the group of epoxysilanes (preferably 3- (3-aminopropyltriethoxysilane). Glycidyloxy) propyltriethoxysilane and 3- (glycidyloxy) propyltrimethoxysilane),
  • binder composition according to the invention comprising silanes
  • Epoxysilanes preferably selected from the group consisting of 3- (glycidyloxy) propyltriethoxysilane and 3- (glycidyloxy) propyltrimethoxysilane, in a total amount in the range of 0.5 to 1 1 wt .-%, preferably in the range of 2, 5 to 7 wt .-%, particularly preferably 4 to 6 wt .-%, based on the total mass of the binder composition.
  • silanes may be present or (this is preferred) not present.
  • Epoxysilanes in the abovementioned concentrations lead to a higher strength of the resulting foundry moldings in comparison with other silanes at the same concentration.
  • the resulting foundry moldings have proven to be particularly resistant to humidity; They are therefore very long storable even without exclusion of air.
  • a binder composition of the invention (as defined above, preferably as defined above as preferred) wherein the negatively charged or uncharged phenol-aldehyde resin is a negatively charged or uncharged resole-phenol-aldehyde resin for curing with carbon dioxide gas in the phenol-resol-C0 2 process.
  • the phenol-aldehyde resin is preferably present as an (uncharged) resol-phenol-aldehyde resin in an alkaline medium and / or as the alkali salt of the resol. Phenolaldehydharzes ago.
  • the amount of alkali present in the binder composition is preferably sufficient to partially or completely prevent stable complex formation between the resin present in the binder composition and the oxyanion.
  • binder composition of the invention (as defined above, preferably as defined above as preferred), further comprising one or more compounds selected from the group consisting of polyalkylene glycols, phenylalkylene glycol ethers, propylene glycol alkyl ethers, substituted or unsubstituted pyrrolidones, monoethylene glycol and polyethylene glycol in a total amount within the range from 1 to 40% by weight, preferably in a total amount of 1 to 15% by weight, preferably in the range of 2 to 4% by weight, based on the total weight of the binder composition
  • the abovementioned compounds react in individual cases with further components of a binder composition according to the invention.
  • they may react with cations (for example potassium cations) contained in the binder composition, for example similar to the so-called crown ether complexes, and / or they may react with the phenolaldehyde resin or the oxyanions to form ethers.
  • cations for example potassium cations
  • the compounds mentioned above are not to be regarded exclusively as inert solvents, but they appear to additionally accelerate the curing process. In a binder composition according to the invention, therefore, the compounds themselves are present (still unreacted) and / or their reaction products, depending on the particular method of preparation.
  • the phenol-aldehyde resin of a binder composition of the invention is therefore preferred
  • the abovementioned compounds are selected from the group consisting of polyalkylene glycols, phenylalkylene glycol ethers, propylene glycol alkyl ethers, substituted or unsubstituted pyrrolidones, monoethylene glycol and polyethylene glycol in a total amount of from 1 to 15% by weight, preferably in the range of from 2 to 4 Wt .-%, based on the total mass of the binder composition according to the invention, are present, since the resulting foundry moldings have improved storage properties and higher flexural strengths.
  • the one or at least one of the several compounds as defined above is selected from the group of polyethylene glycols, these being present in a total amount of 3 to 15 wt .-%, based on the Total mass of binder composition.
  • binder composition according to the invention (as defined above, preferably as defined above as preferred), also comprising
  • Preferred or particularly preferred binder compositions as defined above have improved flowability compared to binder compositions of the invention which do not contain the compounds defined above.
  • one or both compounds from the group consisting of isononanoic acid and alkali salts of isononanoic acid in a total amount in the range of 0, 1 to 5.0% by weight, preferably in a total amount of 0.5 to 3 wt .-%, preferably in a total amount of from 0.8 to 1.5% by weight, based on the total weight of the binder composition.
  • binder compositions according to the invention which comprise isononanoic acid and / or alkali metal salts of isononanoic acid in the concentrations defined above are advantageous, since such binder compositions have a particularly improved flowability.
  • binder composition of the invention (as defined above, preferably as defined above as preferred)
  • Phenoxyethanol phenylmonoethylene glycol ether
  • butyldiglycol diethylene glycol butyl ether
  • monoethylene glycol in a total amount in the range of 3 to 10 wt .-%, preferably in the range of 3-6 wt.%, Based on the total mass of the binder composition.
  • Preferred binder compositions of the present invention as defined above have the same advantageous technical effects previously defined for preferred binder compositions of the invention comprising one or more compounds selected from the group consisting of polyalkylene glycols, phenylalkylene glycol ethers, propylene glycol alkyl ethers, substituted or unsubstituted pyrrolidones, monoethylene glycol, and polyethylene glycol ,
  • binder composition according to the invention also comprising
  • 1, 3,5-Trioxacyclohexan in a total amount in the range of 0, 1 to 5%, preferably in the range of 0.5 to 1, 5%.
  • the presence of 1, 3,5-Trioxacyclohexan leads to a special strength of the resulting foundry molding during casting. This advantageous technical effect is presumably due to the fact that the decomposition of the 1, 3,5-Trioxacyclohexan during casting of the foundry mold additional formaldehyde is released, which contributes to an additional cross-linking between the oligomers of the phenol-aldehyde resin and thus to the specific strength of the resulting foundry molded body.
  • binder composition of the invention (as defined above, preferably as defined above as preferred) wherein the pH at 20 ° C is in the range of 12 to 14, preferably in the range of 13 to 14.
  • Binder compositions having a pH of 12 to 14, especially having a pH of 13 to 14, can be stored for a prolonged period of time without a noticeable deterioration in the properties of the binder composition.
  • a binder composition according to the invention (as defined above, preferably as defined above as preferred), wherein the molar amount of the phenol groups in the aqueous alkaline binder composition in the range of 1, 5 to 2.5 mol / kg, preferably in the range of 1, 8 to 2.0 mol / kg, based on the total mass of the binder composition, and / or the viscosity of the alkaline binder composition at 20 ° C in the range of 100-1000 mPas, preferably 150-700 mPas, particularly preferably 150-500 mPas , determined according to DIN EN ISO 3219: 1994.
  • the measuring method see below.
  • Particularly stable (solid) molded foundry bodies can be produced with the preferred binder compositions according to the invention as defined above.
  • the above-defined amount of phenol groups is preferably a component of a phenol-aldehyde resin having an average molecular weight (Mw) in the range of 750 to 1200 g / mol.
  • Mw average molecular weight
  • the mixing of the aqueous alkaline binder composition according to the invention with foundry molding material and the processing of the resulting molding material mixture in a core shooter is particularly unproblematic.
  • binder composition of the invention (as defined above, preferably as defined above as preferred) wherein the molar ratio of the total amount of alkali metals to phenol groups is in the range of 1.0: 1 to 2.5: 1, preferably in the range of 1 , 5: 1 to 2, 1: 1, more preferably in the range of 1, 7: 1 to 1, 9: 1 and or
  • the molar amount of the alkali metals in the aqueous alkaline binder composition is in the range of 1, 0 to 7.5 mol / kg, preferably in the range of 2.0 to 6.0 mol / kg, particularly preferably in the range of 3.0 to 4.0 mol / kg, based on the total weight of the binder composition.
  • binder composition of the invention (as defined above, preferably as defined above as preferred), wherein the molar ratio of the total amount of potassium cations to the total amount of sodium cations is in the range of 47: 1 to 59: 1, preferably Range from 50: 1 to 56: 1, more preferably in the range of 52: 1 to 55: 1.
  • binder compositions according to the invention have the further advantage that they achieve an optimum reactivity for the hardening with carbon dioxide gas by the defined amount or by the defined ratio while at the same time having sufficient shelf life of the binder compositions described above.
  • binder composition according to the invention for curing with carbon dioxide gas in the phenol-Resol-C0 2 method comprising
  • phenol-aldehyde resin selected from the group consisting of resoles and mixtures comprising one or more resoles and one or more novolacs, wherein the phenol-aldehyde resin has an average molecular weight (Mw) in the range of from 750 to 1200 g / mol has, preferably in the range of 800 to 1 100 g / mol and particularly preferably in the range of 850 to 1000 g / mol, determined by means of gel permeation chromatography,
  • an oxyanion selected from the group consisting of borate ions, aluminas, stannate ions, zirconate ions, titanate ions, and mixtures thereof to form a stable complex with the negatively charged or uncharged phenolaldehyde resin
  • one or more epoxysilanes preferably selected from the group consisting of 3-glycidyloxy-propyl-triethoxysilane and 3-glycidyloxy-propyl-trimethoxysilane, in a total amount in the range of 0.5 to 1 1 wt .-%, preferably in the range of 2 From 5 to 10% by weight, based on the total weight of the binder composition, wherein the total molar amount of the phenol groups of the phenolaldehyde resin in the aqueous alkaline binder composition is in the range of 1.8 to 2.0 mol / kg based on the total mass of the aqueous alkaline binder composition.
  • the above-defined specific binder composition according to the invention leads to very particularly solid foundry moldings.
  • the present invention also relates to a use of an aqueous alkaline binder composition as defined above (preferably as defined above as preferred) as a binder for a foundry molding material, preferably in a process in which the binder is cured by gassing with carbon dioxide gas.
  • the present invention also relates to a molding material mixture for producing a foundry molding, comprising
  • an aqueous alkaline binder composition according to the invention as defined above preferably as defined above as preferred
  • foundry shaped body includes in particular cores, molds and feeder elements for use in casting.
  • the aqueous alkaline binder composition is suitable for curing with carbon dioxide gas in the presence of the foundry molding material.
  • the molding mixture as a whole is thus curable with carbon dioxide gas.
  • foundry mold material in particular comprises molding sands, chamottes, hollow spheres and core-shell particles.
  • Foundry moldings are preferably fire-resistant.
  • quartz sand is often used, but also other foundry materials such as Zirkonsande, chromite sands, chamottes, olivine sands, hollow spheres, core-shell particles, feldspat ambience sands and Andalusitsande.
  • the bulk density of the molding material mixture (for producing feeder elements) is preferably 2 g / cm 3 or smaller, preferably 1.6 g / cm 3 or smaller, more preferably 1.2 g / cm 3 or smaller, most preferably 1 g / cm 3 or smaller, more preferably 0.8 g / cm 3 or smaller, ideally 0.7 g / cm 3 or less.
  • the mass ratio of the total amount of aqueous alkaline binder composition according to the invention to the total amount of foundry material in a binder composition according to the invention is preferably in the range from 10: 100 to 0.5: 100, particularly preferably in the range from 5: 100 to 1: 100.
  • the present invention also relates to a method for producing a foundry shaped body (e.g., mold, core or feeder element), comprising the steps of:
  • Hardening of the molded molding mixture by gassing with carbon dioxide gas.
  • a sizing composition is preferably applied to the surface of a foundry molded body (preferably a core) by gassing with carbon dioxide gas after hardening of the molded molding material mixture to smooth the surface structure, resulting in a sized (and thus smoothed) foundry molded body (preferably core).
  • the present invention also relates to a corresponding foundry shaped body (e.g., mold, core or feeder element),
  • a corresponding foundry shaped body e.g., mold, core or feeder element
  • a foundry molded body according to the invention in particular a core according to the invention, is preferably sized. That is, on the surface of the core is or the surface of the core is formed by sizing material. Sizing material is regularly a substance mixture, which in particular comprises refractory material.
  • Bending bars are produced using a core shooter LUT-c from Multiserw.
  • the freshly prepared sand mixture is filled into the shooting head of the machine.
  • the bending bars are shot with a shooting pressure of 5 bar, shot time 3 seconds.
  • the shot Biegestab- precursors are fumigated for 15 seconds with 1 bar C0 2 .
  • the core ie, the resulting flex bar
  • the core is purged with air for 10 seconds and then removed from the core box.
  • the resulting bending rod is stored for a certain period of time (see option a below) or sifted (see option b below).
  • the strength test is carried out after different storage times of the bending rods.
  • the storage time of the bending bars is after removal from the machine
  • the bending bars are stored in a fume hood at 20 ° C (+/- 2 ° C) and a relative humidity of 47% (+/- 2%) until testing.
  • the subsequent strength testing of the bending bars is carried out with a Multiserw testing device LR-u-2e, from Multiserw.
  • a Multiserw testing device LR-u-2e from Multiserw.
  • the respective mounted bending rod is inserted into the machine and broken.
  • the resulting bending bars are stored for one hour in a fume hood and then coated with a water-based wash (Arkopal 6804, Fa. Wegtenes-Albertus).
  • the wet bending bars are oven-dried at 150 ° C for 30 minutes, cooled in a fume hood and the flexural strength of the sized bending bars is then determined according to VDG leaflet P 73 in [N / cm 2 ].
  • the subsequent strength testing of the bending bars is carried out with a Multiserw testing device LR-u-2e, from Multiserw.
  • LR-u-2e the respective sized bending bar is inserted into the machine and broken.
  • the results of the flexural strength measurements of the resulting scalloped bending bars are hereinafter referred to as "post-sizing" flexing bars.
  • the samples were weighed on an analytical balance and a calculated volume of the eluent was added.
  • the set sample concentration was 2 g / L. Subsequently, the samples were dissolved at room temperature in the charged calculated volume of the eluent and injected for measurement without prior filtration.
  • the weight average molecular weight i. average molecular weight Mw, was determined on the basis of the following formula:
  • n, number of molecules of a fraction
  • the viscosity of the aqueous alkaline binder composition was measured at a temperature of 20 ° C by means of the instrument "HAAKE Viscotester 550" Thermo Fisher Scientific in combination with the spindle / measuring device “SV1" according to DIN EN ISO 3219: 1994.
  • GT parts by weight (parts by mass).
  • a binder composition is prepared as follows:
  • a premix is prepared by mixing
  • trioxane i.e., 1, 3,5-trioxacyclohexane
  • the mixture is heated to 65 ° C and
  • the reaction mixture is added to 80 ° C and condensed at a temperature between 80 and 90 ° C until a mixture is present with a viscosity of 300 mPas at 5th production step:
  • reaction mixture is cooled to 40 ° C in less than 5 minutes.
  • binder compositions according to the invention were prepared with various amounts of silane (compare Example 1, 7th production step) and each processed into bending bars as described above. After a different period of storage (see option a) under measuring method (bending strength)) or after finishing (see option b) under measuring method (bending strength)), the strengths of the respective bending bars were determined.
  • FIG. 2 contains a selection of the data from Table 1.
  • FIG. 1 shows flexural strengths of flexural bars produced according to Example 2 with various amounts of silane after 24 hours and after storage for 5 days and after sizing.
  • 10 binder compositions each containing different amounts of silane (0.5 to 10% by weight) were used (see x-axis of FIG To investigate the dependence of the bending strength of the amount of silane used.
  • the numbers in the bars of FIG. 1 refer to the amount of silane in% by weight used for the preparation of the respective bending bar (ie the number "0.5" in the first bar of the "after 24 hours” series of measurements in FIG. that a silane amount of 0.5 wt .-% was used for the production of the bending rod used).
  • FIG. 2 shows a selection of the flexural strengths of the flexural rods produced according to Example 2 with different amounts of silane (after a storage time of 24 hours or 5 days or after sizing).
  • silane after a storage time of 24 hours or 5 days or after sizing.
  • FIG. 2 in contrast to FIG. 1, only the amount of silane in% by weight is indicated on the X-axis. It can be clearly seen in FIG. 2 that all inventive compositions comprising more than 2% by weight of 3-glycidyloxypropyltrimethoxysilane in the measurements "after sizing" and "after 5 days” have higher flexural strengths than those compositions according to the invention in which a lower Silane content is present.
  • Binder compositions were prepared with resoles of various average molecular weights M w, and after a different storage time (see option a) under “method of measurement (flexural strength)” or after sizing (see option b) under “method of measurement (flexural strength)” each bending bars examined for their strength.
  • compositions of the present invention comprising resols having a molecular weight M w of greater than 750 g / mol showed a higher or a higher in all measurements (flex bars after storage for 15 seconds, for 1 hour, for 24 hours, for 5 days, or after sizing) unchanged flexural strengths in comparison with the noninventive mixtures comprising phenol-aldehyde resins and / or their salts having a molecular weight Mw of less than 750 g / mol. This is especially true for the initial strengths (i.e., flexural strength after 15 seconds) and for the flexural strengths of the sized foundry moldings.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Organic Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Health & Medical Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Mold Materials And Core Materials (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
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Abstract

L'invention concerne une composition aqueuse alcaline de liant, à durcir avec du dioxyde de carbone, laquelle comprend une résine phénolaldéhyde chargée négativement ou non chargée, comportant des groupes phénol, laquelle résine est choisie dans le groupe constitué par les résols et des mélanges comprenant un ou plusieurs résols ainsi qu'une ou plusieurs novolaques, un oxyanion, sélectionné dans le groupe constitué par les ions borate, les ions aluminate, les ions stannate, les ions zirconate, les ions titanate et leurs mélanges, de manière à former un complexe stable avec la résine résol-phénolaldéhyde, la quantité totale molaire des groupes phénol de la résine phénolaldéhyde dans la composition alcaline aqueuse de liant étant comprise entre 1 et 3 mole/kg, rapportée à la masse totale de ladite composition alcaline aqueuse de liant et la résine phénolaldéhyde présentant un poids moléculaire moyen (Mw) de l'ordre de 750 à 1200 à 4000 g/mole, déterminé par chromatographie par perméation de gel. L'invention concerne également une utilisation correspondante, un mélange de matières à mouler pour fabriquer un corps de moule de fonderie ainsi qu'un procédé correspondant pour fabriquer un corps de moule de fonderie et un corps de moule de fonderie correspondant.
EP17736600.2A 2016-06-30 2017-06-28 Composition alcaline aqueuse de liant, à durcir avec du dioxyde de carbone, son utilisation, mélange de matières à mouler correspondant pour la fabrication d'un corps de moule de fonderie, corps de moule de fonderie correspondant et procédé de fabrication d'un corps moule de fonderie Withdrawn EP3478429A1 (fr)

Applications Claiming Priority (2)

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DE102016211971.0A DE102016211971A1 (de) 2016-06-30 2016-06-30 Wässrige alkalische Bindemittelzusammensetzung zur Aushärtung mit Kohlendioxidgas sowie deren Verwendung, eine entsprechende Formstoffmischung zur Herstellung eines Gießereiformkörpers, ein entsprechender Gießereiformkörper sowie ein Verfahren zur Herstellung eines Gießereiformkörpers
PCT/EP2017/065976 WO2018002129A1 (fr) 2016-06-30 2017-06-28 Composition alcaline aqueuse de liant, à durcir avec du dioxyde de carbone, son utilisation, mélange de matières à mouler correspondant pour la fabrication d'un corps de moule de fonderie, corps de moule de fonderie correspondant et procédé de fabrication d'un corps moule de fonderie

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EP3478429A1 true EP3478429A1 (fr) 2019-05-08

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EP17736600.2A Withdrawn EP3478429A1 (fr) 2016-06-30 2017-06-28 Composition alcaline aqueuse de liant, à durcir avec du dioxyde de carbone, son utilisation, mélange de matières à mouler correspondant pour la fabrication d'un corps de moule de fonderie, corps de moule de fonderie correspondant et procédé de fabrication d'un corps moule de fonderie

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US (1) US20190255599A1 (fr)
EP (1) EP3478429A1 (fr)
KR (1) KR20190025687A (fr)
CN (1) CN109526211A (fr)
BR (1) BR112018077237A2 (fr)
DE (1) DE102016211971A1 (fr)
MX (1) MX2018016358A (fr)
WO (1) WO2018002129A1 (fr)

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DE102019135605A1 (de) * 2019-12-20 2021-06-24 Ask Chemicals Gmbh Verfahren zum schichtweisen Aufbau von Körpern umfassend feuerfesten Formgrundstoff und Resole, nach diesem Verfahren hergestellte dreidimensionale Körper sowie ein Bindemittel für den 3-dimensionalen Aufbau von Körpern
CN112692226B (zh) * 2020-12-09 2022-08-30 南昌科勒有限公司 一种热芯盒树脂砂及包含其的树脂砂芯

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GB886854A (en) * 1959-02-17 1962-01-10 Courtaulds Ltd Improvements in and relating to binding compositions
US4474904A (en) * 1982-01-21 1984-10-02 Lemon Peter H R B Foundry moulds and cores
US4780489A (en) * 1987-05-15 1988-10-25 Ashland Oil, Inc. Modifiers for aqueous basic solutions of phenolic resole resins
US4977209A (en) 1987-12-24 1990-12-11 Foseco International Limited Production of articles of bonded particulate material and binder compositions for use therein from phenol-formaldehyde and oxyanion
GB9105312D0 (en) 1991-03-13 1991-04-24 Foseco Int Binder compositions
GB9105313D0 (en) 1991-03-13 1991-04-24 Foseco Int Binder compositions
GB9105314D0 (en) 1991-03-13 1991-04-24 Foseco Int Binder compositions
GB9105315D0 (en) 1991-03-13 1991-04-24 Foseco Int Binder compositions
CA2041187C (fr) 1991-04-25 1997-04-22 John Stephen Griffin Production de moules et noyaux de fonderie au sable
GB9203260D0 (en) 1992-02-15 1992-04-01 Foseco Int Alkaline resol phenol-aldehyde resin binder compositions
JPH0890148A (ja) * 1994-09-14 1996-04-09 Sumitomo Durez Co Ltd 鋳型用フェノール樹脂組成物
AU1078797A (en) 1995-11-21 1997-06-11 Ashland Inc. Cold-box process for preparing foundry shapes
JP3453491B2 (ja) * 1996-05-29 2003-10-06 花王株式会社 炭酸ガス硬化用粘結剤組成物
JP4046860B2 (ja) * 1998-07-13 2008-02-13 花王株式会社 鋳型用粘結剤組成物
DE19938043C2 (de) * 1999-08-12 2001-12-06 Ashland Suedchemie Kernfest Aluminiumhaltiges Bindemittelsystem auf Resolbasis, Verfahren zur Herstellung und Verwendung sowie Formmasse
DE10136365A1 (de) 2001-07-26 2003-02-13 Ashland Suedchemie Kernfest CO¶2¶-härtbares Bindemittelsystem auf Resolbasis
DE102005024334A1 (de) 2005-05-27 2006-12-07 Ashland-Südchemie-Kernfest GmbH Cold-Box Bindemittelsystem unter Verwendung von gesättigten Fettsäureestern
PT2052798E (pt) 2008-11-25 2012-01-24 Huettenes Albertus Composições ligantes de fenol aldeído resol alcalino
DE202011110617U1 (de) * 2010-12-16 2015-04-29 Hüttenes-Albertus Chemische Werke GmbH Emissionsarmes kalthärtendes Bindemittel für die Gießereiindustrie

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KR20190025687A (ko) 2019-03-11
US20190255599A1 (en) 2019-08-22
BR112018077237A2 (pt) 2019-04-02
WO2018002129A1 (fr) 2018-01-04
DE102016211971A1 (de) 2018-01-04
MX2018016358A (es) 2019-08-16
CN109526211A (zh) 2019-03-26

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