EP3551360B1 - Liant résol alcalin à fluidité améliorée - Google Patents
Liant résol alcalin à fluidité améliorée Download PDFInfo
- Publication number
- EP3551360B1 EP3551360B1 EP17811304.9A EP17811304A EP3551360B1 EP 3551360 B1 EP3551360 B1 EP 3551360B1 EP 17811304 A EP17811304 A EP 17811304A EP 3551360 B1 EP3551360 B1 EP 3551360B1
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- EP
- European Patent Office
- Prior art keywords
- molding material
- material mixture
- weight
- molding
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- Prior art date
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- 229920003987 resole Polymers 0.000 title claims description 41
- 239000011230 binding agent Substances 0.000 title description 30
- 239000000203 mixture Substances 0.000 claims description 68
- 239000012778 molding material Substances 0.000 claims description 58
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 37
- 239000004576 sand Substances 0.000 claims description 27
- 238000000034 method Methods 0.000 claims description 23
- 239000000463 material Substances 0.000 claims description 20
- 238000000465 moulding Methods 0.000 claims description 20
- TZIHFWKZFHZASV-UHFFFAOYSA-N methyl formate Chemical compound COC=O TZIHFWKZFHZASV-UHFFFAOYSA-N 0.000 claims description 18
- 238000005266 casting Methods 0.000 claims description 17
- 125000000217 alkyl group Chemical group 0.000 claims description 13
- 150000002148 esters Chemical class 0.000 claims description 12
- 238000004519 manufacturing process Methods 0.000 claims description 11
- 239000007788 liquid Substances 0.000 claims description 9
- 239000007787 solid Substances 0.000 claims description 6
- 229910052782 aluminium Inorganic materials 0.000 claims description 5
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 5
- 125000004432 carbon atom Chemical group C* 0.000 claims description 5
- 239000011521 glass Substances 0.000 claims description 4
- YKTSYUJCYHOUJP-UHFFFAOYSA-N [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] Chemical compound [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] YKTSYUJCYHOUJP-UHFFFAOYSA-N 0.000 claims description 3
- 239000002245 particle Substances 0.000 claims description 3
- 238000006116 polymerization reaction Methods 0.000 claims description 3
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 2
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- 239000008187 granular material Substances 0.000 claims description 2
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- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 claims description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims 2
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- -1 aluminate ions Chemical class 0.000 description 13
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- HEMHJVSKTPXQMS-UHFFFAOYSA-M sodium hydroxide Inorganic materials [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 5
- BTBUEUYNUDRHOZ-UHFFFAOYSA-N Borate Chemical compound [O-]B([O-])[O-] BTBUEUYNUDRHOZ-UHFFFAOYSA-N 0.000 description 4
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 4
- 230000000996 additive effect Effects 0.000 description 4
- 150000008044 alkali metal hydroxides Chemical class 0.000 description 4
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- CZMRCDWAGMRECN-UGDNZRGBSA-N Sucrose Chemical compound O[C@H]1[C@H](O)[C@@H](CO)O[C@@]1(CO)O[C@@H]1[C@H](O)[C@@H](O)[C@H](O)[C@@H](CO)O1 CZMRCDWAGMRECN-UGDNZRGBSA-N 0.000 description 3
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- 239000003054 catalyst Substances 0.000 description 3
- 238000006243 chemical reaction Methods 0.000 description 3
- 239000008103 glucose Substances 0.000 description 3
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 3
- 229920006395 saturated elastomer Polymers 0.000 description 3
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- YEJRWHAVMIAJKC-UHFFFAOYSA-N 4-Butyrolactone Chemical compound O=C1CCCO1 YEJRWHAVMIAJKC-UHFFFAOYSA-N 0.000 description 2
- FBPFZTCFMRRESA-FSIIMWSLSA-N D-Glucitol Natural products OC[C@H](O)[C@H](O)[C@@H](O)[C@H](O)CO FBPFZTCFMRRESA-FSIIMWSLSA-N 0.000 description 2
- 229930091371 Fructose Natural products 0.000 description 2
- 239000005715 Fructose Substances 0.000 description 2
- RFSUNEUAIZKAJO-ARQDHWQXSA-N Fructose Chemical compound OC[C@H]1O[C@](O)(CO)[C@@H](O)[C@@H]1O RFSUNEUAIZKAJO-ARQDHWQXSA-N 0.000 description 2
- WNLRTRBMVRJNCN-UHFFFAOYSA-N adipic acid Chemical compound OC(=O)CCCCC(O)=O WNLRTRBMVRJNCN-UHFFFAOYSA-N 0.000 description 2
- 150000001412 amines Chemical class 0.000 description 2
- 239000007864 aqueous solution Substances 0.000 description 2
- WQZGKKKJIJFFOK-VFUOTHLCSA-N beta-D-glucose Chemical compound OC[C@H]1O[C@@H](O)[C@H](O)[C@@H](O)[C@@H]1O WQZGKKKJIJFFOK-VFUOTHLCSA-N 0.000 description 2
- KGBXLFKZBHKPEV-UHFFFAOYSA-N boric acid Chemical compound OB(O)O KGBXLFKZBHKPEV-UHFFFAOYSA-N 0.000 description 2
- 150000001720 carbohydrates Chemical class 0.000 description 2
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- KVVSCMOUFCNCGX-UHFFFAOYSA-N cardol Chemical compound CCCCCCCCCCCCCCCC1=CC(O)=CC(O)=C1 KVVSCMOUFCNCGX-UHFFFAOYSA-N 0.000 description 2
- RTZKZFJDLAIYFH-UHFFFAOYSA-N ether Substances CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 description 2
- LEQAOMBKQFMDFZ-UHFFFAOYSA-N glyoxal Chemical compound O=CC=O LEQAOMBKQFMDFZ-UHFFFAOYSA-N 0.000 description 2
- 239000004005 microsphere Substances 0.000 description 2
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 2
- 235000019353 potassium silicate Nutrition 0.000 description 2
- 238000007493 shaping process Methods 0.000 description 2
- 150000004756 silanes Chemical class 0.000 description 2
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 2
- 239000002904 solvent Substances 0.000 description 2
- 239000000600 sorbitol Substances 0.000 description 2
- 238000003756 stirring Methods 0.000 description 2
- 150000003606 tin compounds Chemical class 0.000 description 2
- URAYPUMNDPQOKB-UHFFFAOYSA-N triacetin Chemical compound CC(=O)OCC(OC(C)=O)COC(C)=O URAYPUMNDPQOKB-UHFFFAOYSA-N 0.000 description 2
- WYTZZXDRDKSJID-UHFFFAOYSA-N (3-aminopropyl)triethoxysilane Chemical compound CCO[Si](OCC)(OCC)CCCN WYTZZXDRDKSJID-UHFFFAOYSA-N 0.000 description 1
- PRAKNSGQZLPYMI-ZNTWSVFFSA-N (4S,5R,6R)-2,4,5,6,7-pentahydroxyheptan-3-one Chemical compound CC(O)C(=O)[C@@H](O)[C@H](O)[C@H](O)CO PRAKNSGQZLPYMI-ZNTWSVFFSA-N 0.000 description 1
- RTBFRGCFXZNCOE-UHFFFAOYSA-N 1-methylsulfonylpiperidin-4-one Chemical compound CS(=O)(=O)N1CCC(=O)CC1 RTBFRGCFXZNCOE-UHFFFAOYSA-N 0.000 description 1
- JOLVYUIAMRUBRK-UHFFFAOYSA-N 11',12',14',15'-Tetradehydro(Z,Z-)-3-(8-Pentadecenyl)phenol Natural products OC1=CC=CC(CCCCCCCC=CCC=CCC=C)=C1 JOLVYUIAMRUBRK-UHFFFAOYSA-N 0.000 description 1
- JTXMVXSTHSMVQF-UHFFFAOYSA-N 2-acetyloxyethyl acetate Chemical compound CC(=O)OCCOC(C)=O JTXMVXSTHSMVQF-UHFFFAOYSA-N 0.000 description 1
- YLKVIMNNMLKUGJ-UHFFFAOYSA-N 3-Delta8-pentadecenylphenol Natural products CCCCCCC=CCCCCCCCC1=CC=CC(O)=C1 YLKVIMNNMLKUGJ-UHFFFAOYSA-N 0.000 description 1
- RMTFNDVZYPHUEF-XZBKPIIZSA-N 3-O-methyl-D-glucose Chemical compound O=C[C@H](O)[C@@H](OC)[C@H](O)[C@H](O)CO RMTFNDVZYPHUEF-XZBKPIIZSA-N 0.000 description 1
- GUBGYTABKSRVRQ-XLOQQCSPSA-N Alpha-Lactose Chemical compound O[C@@H]1[C@@H](O)[C@@H](O)[C@@H](CO)O[C@H]1O[C@@H]1[C@@H](CO)O[C@H](O)[C@H](O)[C@H]1O GUBGYTABKSRVRQ-XLOQQCSPSA-N 0.000 description 1
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- 150000003839 salts Chemical class 0.000 description 1
- 238000007127 saponification reaction Methods 0.000 description 1
- 238000007873 sieving Methods 0.000 description 1
- 229910001388 sodium aluminate Inorganic materials 0.000 description 1
- NVIFVTYDZMXWGX-UHFFFAOYSA-N sodium metaborate Chemical compound [Na+].[O-]B=O NVIFVTYDZMXWGX-UHFFFAOYSA-N 0.000 description 1
- 239000004328 sodium tetraborate Substances 0.000 description 1
- 235000010339 sodium tetraborate Nutrition 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 229940071182 stannate Drugs 0.000 description 1
- 125000005402 stannate group Chemical group 0.000 description 1
- 150000005846 sugar alcohols Polymers 0.000 description 1
- 150000008163 sugars Chemical group 0.000 description 1
- 230000000930 thermomechanical effect Effects 0.000 description 1
- 229960002622 triacetin Drugs 0.000 description 1
- WYXIGTJNYDDFFH-UHFFFAOYSA-Q triazanium;borate Chemical compound [NH4+].[NH4+].[NH4+].[O-]B([O-])[O-] WYXIGTJNYDDFFH-UHFFFAOYSA-Q 0.000 description 1
- BPSIOYPQMFLKFR-UHFFFAOYSA-N trimethoxy-[3-(oxiran-2-ylmethoxy)propyl]silane Chemical compound CO[Si](OC)(OC)CCCOCC1CO1 BPSIOYPQMFLKFR-UHFFFAOYSA-N 0.000 description 1
- 238000009827 uniform distribution Methods 0.000 description 1
- 238000005406 washing Methods 0.000 description 1
- 239000000811 xylitol Substances 0.000 description 1
- HEBKCHPVOIAQTA-SCDXWVJYSA-N xylitol Chemical compound OC[C@H](O)[C@@H](O)[C@H](O)CO HEBKCHPVOIAQTA-SCDXWVJYSA-N 0.000 description 1
- 235000010447 xylitol Nutrition 0.000 description 1
- 229960002675 xylitol Drugs 0.000 description 1
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
- B22C1/02—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives
- B22C1/10—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives for influencing the hardening tendency of the mould material
-
- 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
- B22C1/20—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
Definitions
- the invention relates to molding mixtures for the production of molds, cores or feeders for metal casting, comprising at least one refractory base molding material, a binder based on an alkaline resol resin and at least one sugar surfactant.
- the invention also relates to a method for producing molds and cores using the molding material mixtures and to molds, cores and feeders produced by this method.
- Casting molds are essentially composed of molds or molds and cores, which represent the negative shape of the casting to be produced.
- These molds and cores generally consist of a refractory basic molding material, for example quartz sand, and a suitable binding agent which gives the casting mold sufficient mechanical strength after it has been removed from the mold.
- the refractory basic molding material is preferably in free-flowing form so that, after mixing with the binder, it can be filled into a suitable hollow mold, compacted and then cured. After curing, the binding agent ensures that the particles of the basic mold material are held together firmly so that the casting mold has the required mechanical stability.
- molds form the outer wall for the casting, cores are used to form cavities within the casting. It is not absolutely necessary that the molds and cores are made of the same material. In chill casting, for example, the external shaping of the cast pieces is done with the help of permanent metallic molds. A combination of molds and cores that have been produced from differently composed molding material mixtures and using different processes is also possible. Feeders are cavities in the casting mold that are filled with liquid metal together with the casting during casting. The feeder keeps the metal in it liquid longer and can thus compensate for a volume deficit in the solidification phase of the casting.
- organic, inorganic and mixed organic / inorganic binders can be used, the hardening of which can take place in each case by cold or hot processes.
- Cold processes are those processes that are carried out essentially without heating the mold used to manufacture the core, usually at room temperature or at a temperature caused by any reaction.
- the hardening takes place, for example, in that a gas is passed through the molding material mixture to be hardened, thereby triggering a chemical reaction.
- the molding material mixture is e.g. heated by the heated mold to a sufficiently high temperature to drive off the solvent contained in the binder and / or to initiate a chemical reaction by which the binder is hardened.
- alkaline phenolic resins as binders for casting molds is known per se and these are for example in the EP 0323096 B2 and in the EP 1228128 B1 disclosed. These are alkaline resol resins that can be hardened by introducing CO 2 .
- Essential components of the binders described in the patents mentioned are oxyanions, e.g. the borate ion ( EP 032096 B2 ) or the combination of borate and aluminate ions ( EP 1228128 B1 ).
- Molding mixtures with alkaline resole resins often show poor flowability. This is noticeable in that fine core areas are incompletely depicted, the cores are not compactly compressed and thus lose strength or the molding material mixture in the shooting head stalls and does not continue to flow. In the latter case, a cavity then forms and the sand can only be pushed in by mechanical tamping.
- Various proposals have already been made to address this problem.
- US 5376696 or the WO 92/01016 A1 describe sand mixtures for ester-hardening alkaline resole resins, in which a surfactant solution is added to the sand mixture to improve the flowability.
- EP 0399636 A2 describes ester-hardening alkaline resole resins which contain a fluorosurfactant, which can have an anionic, cationic, amphoteric or nonionic character.
- JP 3 250915 B2 discloses molding material mixtures with alkaline resols and various surfactants, including sugar esters.
- DE 10 2012 104934 A1 discloses waterglass-based molding material mixtures with various surfactants, including polyglycosides based on fatty alcohol.
- DE 10 2007 051850 A1 discloses waterglass-based molding material mixtures with various surfactants, including carbohydrates etherified with alkyl groups.
- the object of the invention is therefore to improve the flowability of the basic molding material impregnated with an alkaline resol.
- Claim 13 describes a method for producing a core, feeder or a mold
- claim 14 describes a mold, feeder or a core.
- sugar surfactants significantly improves the flowability of mixtures of alkaline resole resin and refractory basic molding materials. This is surprising insofar as the surface tension of an alkaline resole resin is only slightly reduced by a sugar surfactant.
- the sugar surfactant i used according to the invention is an alkyl polyglycoside and is contained in the alkaline resole resin component or it is added pure or diluted as the second component directly to the molding material mixture before or during mixing.
- the binders are alkaline resole resins.
- the resoles are produced by the condensation of phenolic compounds and aldehyde compounds in the presence of a basic catalyst such as ammonium hydroxide or an alkali metal hydroxide. Alkali metal hydroxide catalysts are preferably used.
- the resoles are used in a concentration of 0.8% by weight to 10% by weight, preferably from about 1% by weight to about 5% by weight and particularly preferably from about 1% by weight to about 4% by weight. % used, each based on the solids content of the resol (according to DIN EN ISO 3251) and the basic molding material.
- concentration of binder within the casting mold can vary.
- Resoles in the sense of the present invention are aromatics linked to one another via methylene groups (-CH 2 -) groups and / or via ether bridges (in particular -CH 2 -O-CH 2 -), each of which has at least one -OH group (phenol compound) .
- Suitable phenolic compounds are phenols, substituted phenols, e.g. Cresols or nonylphenol, 1,2-dihydroxybenzene (catechol), 1,3-dihydroxybenzene (resorcinol), cashew nut shell oil, i.e. a mixture of cardanol and cardol, or 1,4-dihydroxybenzene (hydroquinone) or phenolic compounds such as e.g. Bisphenol A.
- aldehyde compounds examples include formaldehyde, paraformaldehyde and glyoxal and mixtures thereof.
- Formaldehyde or mixtures containing predominantly formaldehyde are particularly preferred.
- the molar ratio of phenol compound to aldehyde compound is preferably between 1.05: 1.2 to 1.05: 2.6, particularly preferably between 1.1: 1.3 to 1.1: 2.5.
- Resoles are preferred in which adjacent hydroxy aromatics are each linked at the ortho and / or para position (relative to the hydroxy group of the built-in phenol / aromatics) via the methylene bridges and / or the ether bridges, i.e. the majority of the links are para and / or ortho.
- Suitable oxyanions in the binder composition for the resole / CO 2 process include borate, stannate and aluminate ions. Aluminate and borate ions are preferred.
- the oxyanion can be added to the binder composition for the resol / CO 2 process by mixing in sodium tetraborate times x H 2 O, potassium tetraborate times x H 2 O, sodium metaborate, sodium pentaborate, sodium stannate trihydrate, sodium aluminate, potassium aluminate, aluminum hydroxide, aluminum oxide or ammonium oxyanion salt such as ammonium borate. Borate ions can also be introduced by adding boric acid or boron oxide.
- the molar ratio of oxyanions (expressed as boron and / or aluminum and / or tin) to phenol group is preferably in the range from 0.1: 1 to 1: 1.
- the molar ratio of boron to phenol is particularly preferably in the range 0.1: 1 to 0.5: 1.
- the oxyanions can also be obtained by introducing organic boron, aluminum and tin compounds such as aluminum alcoholates of the formula Al (OR) 3 , where R can independently be a saturated or unsaturated, branched or unbranched hydrocarbon radical with 1 to 10 carbon atoms.
- a solution of a boron compound such as boric acid or boric acid ester in alkali is suitable as a solution of a boron-containing oxyanion.
- the solution of a base in water, which is also used for mixing with the resole resin, serves as the lye.
- Organic bases such as e.g. Amines or ammonium compounds as well as inorganic bases such as e.g. Alkali metal hydroxides can be used.
- Alkali hydroxides such as e.g. Sodium hydroxide and potassium hydroxide are used.
- the molar ratio of hydroxide ions to the phenol group in the binder system is preferably 0.5: 1 to 3: 1, preferably 1.0: 1 to 2.5: 1. It is not necessary that the total amount of base is already at the beginning of the Condensation is added; The addition is usually carried out in two or more sub-steps, some of which can also only be added at the end of the manufacturing process. Mixtures of basic catalysts can also be used.
- alkaline resoles are for example in the EP 0323096 B2 and EP 1228128 B1 disclosed. Further binders based on resol are for example in the US 4426467 and the US 4474904 described.
- the resole contains water, preferably in an amount of 15% by weight to 50% by weight, based on the binder.
- components of the binding agent are resol, water, alkalis and oxyanion.
- the water can come from aqueous solutions that are used in the production of binders, on the other hand, it can also be added separately to the binder or come as condensation water from the resol condensation.
- water also serves, for example, to give the binder an application-appropriate viscosity (25 ° C.) of 5 to 1200 mPas, preferably from 10 to 1100 mPas and particularly preferably from 10 to 950 mPas.
- the viscosity is determined with the aid of a Brookfield rotary viscometer, " Small Sample” method, spindle no. 21 at 100 rpm and 25 ° C.
- the alkaline resole preferably has a pH value (at 25 ° C.) greater than 12.
- additives such as Alcohols, glycols, and silanes may be added.
- additives such as Alcohols, glycols, and silanes.
- silanes has a particularly positive effect in this regard, e.g. gamma-aminopropyltriethoxysilane or gamma-glycidoxypropyltrimethoxysilane, in concentrations of about 0.1% by weight to about 4.0% by weight, preferably from about 0.2% by weight to about 3.0% by weight and particularly preferably from about 0.3% by weight to about 2.5% by weight, each based on the weight of the molding material composition.
- concentrations e.g. gamma-aminopropyltriethoxysilane or gamma-glycidoxypropyltrimethoxysilane, in concentrations of about 0.1% by weight to about 4.0% by weight, preferably from about 0.2% by weight to about 3.0% by weight and particularly preferably from about 0.3% by weight to about 2.5% by weight, each based on the weight of the molding material composition.
- esters suitable for hardening the resols are, for example, from those skilled in the art US 4426467 , US 4474904 and US 5405881 known. They include lactones, organic carbonates and esters of C1 to C10 mono- and polycarboxylic acids with C1 to C10 mono- and polyalcohols. Preferred but non-limiting examples of these compounds are gamma-butyrolactone, propylene carbonate, ethylene glycol diacetate, mono-, di- and triacetin and the dimethyl esters of succinic acid, glutaric acid and adipic acid, including their mixture known under the name DBE. Due to the different saponification rates of the individual esters, the rate of hardening of the resols varies depending on the ester used, which can also influence the strengths. The desired curing time can be varied within wide limits by mixing two or more esters.
- Carbon dioxide or methyl formate as an aerosol or heated as a gas is also suitable for hardening the resols.
- Sugar surfactants are nonionic surfactants in which sugars form the hydrophilic part of the surfactant molecule. Fatty alcohol or fatty acid residues act as hydrophobic components. Carbohydrates used are, for example, glucose, methylglucose, fructose, methylfructose, lactose, ribose, sucrose, xylenose, xylitol, mannose, mannitol, isosorbitol and sorbitol.
- the sugar building blocks can be used as monomers or up to a degree of polymerization of 30.
- the sugar building blocks can be alpha or beta 1,4 glycosidically linked.
- the hydrophilic component is preferably formed by linking glucose, sucrose, fructose, isosorbitol and / or sorbitol; sucrose and / or glucose is particularly preferred.
- Fatty acids can be esterified or fatty alcohols and / or fatty alcohol ethoxylates, fatty alcohol propoxylates and / or fatty alcohol ethoxylates / fatty alcohol propoxylates, the chain length is between C 6 and C 32 , in particular C 8 and C 22 , and can be branched or straight-chain and saturated to the free hydroxyl groups or be unsaturated. Both the sugar and the fat building blocks can be mixed together.
- alkyl polyglycosides APG
- alkyl polyglucosides are used which have the following exemplary structure.
- n stands on average for 1 to 30, preferably on average from 2 to 25 and particularly preferably on average from 2 to 10.n stands for a saturated or unsaturated, straight-chain or branched alkyl radical with an average of 5 to 31 carbon atoms and particularly preferably 7 to 21 carbon atoms.
- Alkyl polyglycosides are produced on an industrial scale and sold by BASF under the trade names Plantacare or Glucopon.
- the sugar surfactants according to the invention are preferably added to the resole resin in a concentration of 0.05 to 5.0% by weight. Preferably in a range from 0.05 to 3.0% by weight and particularly preferably from 0.05 to 2.0% by weight, relative to the binder.
- the sugar surfactants according to the invention can be added directly to the molding material mixture. This can be done as a pure substance or dissolved in a carrier medium (e.g. water). Based on the finished molding material mixture, 0.005 to 0.5% by weight, preferably 0.01 to 0.3% by weight, of sugar surfactant are added.
- the sugar surfactants used preferably have an HLB value between 11 and 16 (HLB stands for hydrophilic-lipophilic balance).
- basic molding material Conventional materials for the production of casting molds can be used as the refractory basic molding material (hereinafter abbreviated to basic molding material (s)).
- basic molding material for example, quartz sand, zircon sand or chrome ore sand, olivine, vermiculite, bauxite and chamotte or mixtures thereof are suitable. If there are no technological reasons to the contrary, quartz sand is preferred for economic reasons.
- Regenerated materials obtained by washing and subsequent drying are particularly suitable.
- Regenerated materials obtained by thermo-mechanical or purely mechanical treatment can also be used.
- the mean diameter of the basic mold materials is generally between 100 ⁇ m and 600 ⁇ m, preferably between 120 ⁇ m and 550 ⁇ m and particularly preferably between 150 ⁇ m and 500 ⁇ m.
- the particle size can be e.g. determine by sieving according to DIN ISO 3310.
- Artificial molding materials can also be used as molding base materials, in particular as an additive to the above molding base materials, but also as exclusive molding base material, such as glass beads, glass granulate, the spherical ceramic molding base materials known under the name "Cerabeads” or “Carboaccucast” or aluminum silicate microbeads (so-called hollow spheres). Microspheres). Such hollow aluminum silicate microspheres are marketed, for example, by Omega Minerals Germany GmbH, Norderstedt, under the name “Omega-Spheres”. Corresponding products are also available from PQ Corporation (USA) under the name “Extendospheres”.
- the procedure is generally that the refractory molding base material is initially introduced and then the binder and the sugar surfactant are added together or one after the other with stirring. It is of course also possible to add all or some of the components first and then to stir and / or during this. The mixture is stirred until a uniform distribution of the binder and the sugar surfactant with the basic molding material is guaranteed.
- the molding material mixture is then brought into the desired shape.
- the usual methods are used for shaping.
- the molding material mixture can be shot into the tool by means of a core shooting machine with the aid of compressed air.
- Another possibility is to allow the molding material mixture to trickle freely from the mixer into the molding tool and to compress it there by shaking, tamping or pressing.
- the preferred core production process is the resole / CO 2 process.
- this does not exclude gassing with lower alkyl esters, known under the name Betaset processes such as C1 to C3 alkyl formates, in particular methyl formate, and curing by means of liquid esters, known under the name Alphaset process.
- Curing takes place in that CO 2 , a CO 2 / gas mixture (e.g. with air), a gas mixture (e.g. air) or gaseous methyl formate (in the Betaset process) one after the other (as e.g. in detail in the DE 102012103705.1 described) is passed through the mold or through the molding material mixture contained therein.
- a CO 2 / gas mixture e.g. with air
- a gas mixture e.g. air
- gaseous methyl formate in the Betaset process
- the gas stream has a temperature between 0 ° C and 140 ° C, preferably from 5 ° C to 120 ° C and particularly preferably from 6 ° C to 110 ° C.
- Table 1 shows the surface tensions found (in mN / mm) at room temperature, which were obtained by adding the surfactants. If one looks at the surface tension (comparison of the same amount of active substance, identifier with “*”), it is surprisingly noticeable that the APG type sugar surfactants according to the invention reduce the surface tension by only 2% (zero example for B2).
- a sand mixture of quartz sand H 32, plus 3.0% NOVANOL 165 (without or with the listed substances) was mixed homogeneously in a Hobart mixer for 2 minutes. This sand mixture was transferred to a core shooting machine, model Laempe L 1 (opening at the sand outlet of the shooting head reduced to 5mm) and was placed in a four core box (GF bar 220mm x 22.4mm x 22.4 mm) with a shooting pressure of 2 bar using compressed air and a shooting time of 1 sec into the mold. The sand was hardened by means of CO 2 gas (2 liters / min for 30 seconds). After three shots, without the 1 liter shooting head being filled, the sand mixture was visually assessed to determine whether the sand was flowing.
- Table 2 shows that the flexural strengths measured immediately with the Plantacare 2000 UP according to the invention (example B1-B4) remain constant with increasing concentration, while they decrease with increasing oleic acid content (example A1-A4).
- the remaining sand in the firing head was assessed visually.
- “Stuck” means that a cavity has formed above the shooting openings in which the sand does not slide.
- “Slips” means that the cavity does not exist and has been closed by sliding sand. This means that shooting can continue without shaking. This effect is surprising for the sugar surfactants according to the invention (here Plantacare 2000 UP), since it encourages the sand to slide down.
- a sand mixture of quartz sand H 31, plus 2.3% AVENOL F 633 (without or with the listed substances) was mixed homogeneously for 2 minutes in a Hobart mixer.
- This sand mixture was transferred to a core shooter, model Roeper H 1 (opening at the sand outlet of the shooting head 10 mm) and was in a two core box (GF bar 220mm x 22.4mm x 22.4 mm) with a shooting pressure of 3 bar by means of compressed air and brought into the mold with a shooting time of 1 sec.
- the sand was hardened by means of methyl formate gas at 60 ° C. (2.0 ml of liquid methyl formate, for 20 seconds, 2 bar flushing pressure).
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Mold Materials And Core Materials (AREA)
Claims (14)
- Mélange de matières de moulage comprenant au moins une matière de base de moulage réfractaire, un résol alcalin et un alkylpolyglycoside, dans lequel le résol alcalin est présent en une quantité de 0,8 à 10 % en poids, par rapport à la teneur en solides du résol alcalin et par rapport au poids de la matière de base de moulage réfractaire, dans le mélange de matières de moulage.
- Mélange de matières de moulage selon la revendication 1, dans lequel l'alkylpolyglycoside présente un degré de polymérisation de 1 à 30, en particulier de 1 à 10, et un nombre de C du résidu alcool de 6 à 32.
- Mélange de matières de moulage selon la revendication 1, dans lequel l'alkylpolyglycoside présente un degré de polymérisation de 1 à 30, en particulier de 1 à 10, et un nombre de C du résidu alcool de 8 à 22.
- Mélange de matières de moulage selon au moins l'une des revendications précédentes, dans lequel l'alkylpolyglycoside présente une valeur HLB de 11 à 16.
- Mélange de matières de moulage selon au moins l'une des revendications précédentes, dans lequel l'alkylpolyglycoside est présent à un taux de 0,05 à 5,0 % en poids dans le mélange de matières de moulage, de préférence à un taux de 0,05 à 3,0 % en poids et de manière particulièrement préférée à un taux de 0,05 à 2,0 % en poids, par rapport à la teneur en solides du résol alcalin.
- Mélange de matières de moulage selon au moins l'une des revendications précédentes, dans lequel l'alkylpolyglycoside est présent à un taux de 0,005 à 0,5 % en poids dans le mélange de matières de moulage, de préférence à un taux de 0,01 à 0,3 % en poids, par rapport au mélange de matières de moulage.
- Mélange de matières de moulage selon au moins l'une des revendications précédentes, dans lequel le résol alcalin est présent en une quantité de 1 à 5 % en poids, par rapport à la teneur en solide du résol alcalin et par rapport au poids de la matière de base de moulage réfractaire, dans le mélange de matières de moulage.
- Mélange de matières de moulage selon au moins l'une des revendications précédentes, dans lequel le résol alcalin contient des anions oxy, de préférence des composés oxo-aluminium et/ou des composés oxo-bore.
- Mélange de matières de moulage selon au moins l'une des revendications précédentes, dans lequel les résols sont mis en œuvre sous la forme d'une solution aqueuse alcaline, de préférence à une proportion de corps solides de 15 à 50 % en poids, et à une valeur de pH supérieure à 12.
- Mélange de matières de moulage selon au moins l'une des revendications précédentes, dans lequel la matière de base de moulage réfractaire comprend du sable de quartz, du sable de zircone ou du sable de minerai de chrome, de l'olivine, de la vermiculite, de la bauxite, de chamotte, des perles de verre, du granulé de verre, des microsphères de silicate d'aluminium et leurs mélanges, et se compose de préférence à un taux supérieur à 50 % en poids de sable de quartz, par rapport à la matière de base de moulage réfractaire.
- Mélange de matières de moulage selon au moins l'une des revendications précédentes, dans lequel plus de 80 % en poids, de préférence plus de 90 % en poids et de manière particulièrement préférée plus de 95 % en poids du mélange de matières de moulage est la matière de base de moulage réfractaire.
- Mélange de matières de moulage selon au moins l'une des revendications précédentes, dans lequel la matière de base de moulage réfractaire présente des diamètres moyens de particules de 100 µm à 600 µm, de préférence entre 120 µm et 550 µm, déterminés par analyse au tamis.
- Procédé de fabrication d'un noyau, d'une masselotte ou d'un moule, comprenant les étapes suivantes, consistant à :introduire le mélange de matières de moulage selon au moins l'une des revendications précédentes, le cas échéant contenant d'autres composants, dans un outil de moulage ;durcir le mélange de matières de moulage dans l'outil de moulage avec du CO2, du formiate de méthyle ou un autre ester liquide à 25°C, de préférence avec du CO2 ; etprélever le noyau durci, la masselotte durcie ou le moule durci de l'outil de moulage.
- Moule, masselotte ou noyau pouvant être fabriqué(e) d'après le procédé selon la revendication 13 pour la coulée du métal, en particulier la coulée du fer ou de l'aluminium.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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DE102016123661.6A DE102016123661A1 (de) | 2016-12-07 | 2016-12-07 | Alkalische Resolbinder mit verbesserter Fließfähigkeit |
PCT/EP2017/081934 WO2018104493A1 (fr) | 2016-12-07 | 2017-12-07 | Liant résol alcalin à fluidité améliorée |
Publications (2)
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EP3551360A1 EP3551360A1 (fr) | 2019-10-16 |
EP3551360B1 true EP3551360B1 (fr) | 2020-11-25 |
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EP17811304.9A Active EP3551360B1 (fr) | 2016-12-07 | 2017-12-07 | Liant résol alcalin à fluidité améliorée |
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EP (1) | EP3551360B1 (fr) |
DE (1) | DE102016123661A1 (fr) |
WO (1) | WO2018104493A1 (fr) |
Citations (1)
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DE102007051850A1 (de) * | 2007-10-30 | 2009-05-07 | Ashland-Südchemie-Kernfest GmbH | Formstoffmischung mit verbesserter Fliessfähigkeit |
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FR2473032A1 (fr) | 1980-01-07 | 1981-07-10 | Banquy David | Procede de production d'ammoniac et du gaz de synthese correspondant |
US4426467A (en) | 1981-01-12 | 1984-01-17 | Borden (Uk) Limited | Foundry molding compositions and process |
US4474904A (en) | 1982-01-21 | 1984-10-02 | Lemon Peter H R B | Foundry moulds and cores |
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 |
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JP3250915B2 (ja) * | 1994-09-30 | 2002-01-28 | 花王株式会社 | 鋳型用粘結剤組成物、鋳型組成物および鋳型の製造方法 |
DE19938043C2 (de) | 1999-08-12 | 2001-12-06 | Ashland Suedchemie Kernfest | Aluminiumhaltiges Bindemittelsystem auf Resolbasis, Verfahren zur Herstellung und Verwendung sowie Formmasse |
JP2001219242A (ja) * | 2000-02-08 | 2001-08-14 | Hodogaya Ashland Kk | 鋳物砂用粘結剤組成物及び鋳型組成物 |
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2016
- 2016-12-07 DE DE102016123661.6A patent/DE102016123661A1/de not_active Withdrawn
-
2017
- 2017-12-07 EP EP17811304.9A patent/EP3551360B1/fr active Active
- 2017-12-07 WO PCT/EP2017/081934 patent/WO2018104493A1/fr active Search and Examination
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DE102007051850A1 (de) * | 2007-10-30 | 2009-05-07 | Ashland-Südchemie-Kernfest GmbH | Formstoffmischung mit verbesserter Fliessfähigkeit |
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PATRICK BILLIAN ET AL: "Isolation of n -Decyl-[alpha](1->6) Isomaltoside from a Technical APG Mixture and Its Identification by the Parallel Use of LC-MS and NMR Spectroscopy", ANALYTICAL CHEMISTRY, vol. 72, no. 20, 13 September 2000 (2000-09-13), US, pages 4973 - 4978, XP055522388, ISSN: 0003-2700, DOI: 10.1021/ac0004005 * |
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DE102016123661A1 (de) | 2018-06-07 |
EP3551360A1 (fr) | 2019-10-16 |
WO2018104493A1 (fr) | 2018-06-14 |
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