MXPA98010884A - Aglomerantes for nucleos and mol - Google Patents

Abstract

The present invention relates to: non-cooking inorganic binder compositions for agglomerating particulate materials and methods for curing such inorganic binders. The inorganic binder compositions are composed of silicate and phosphate components. The non-cooking compositions further contain curing catalyst such as, for example, a catalyst selected from the group consisting of aliphatic carbonates, cyclic alkylene carbonates, aliphatic carboxylic acid esters, cyclic carboxylic acid esters, phosphate esters, and mixtures thereof. same. The composition produces a binder having the advantageous strength properties of a silicate binder system with the water decomposition properties of a phosphate binder system. Thus, in comparison with a binder system consisting exclusively of silicate, the present invention has an improved water removal capacity by shaking and an improved capacity of water decomposition. Likewise, in comparison with a conventional binder system consisting exclusively of phosphate, the present invention has a superior thermal resistance, that is, the cores and casting molds do not soften at elevated temperatures. Methods for making and using the binder compositions as well as the resulting products are of particular interest in the field of smelting.

Description

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AGGLOMERANTS FOR NUCLEI AND MOLDS FIELD OF THE INVENTION The present invention relates generally to "non-cooking" inorganic binder systems for 5-particle material which has particular utility in the manufacture of molds, cores, mandrels, or other forms that they can be used in the production of metallic and non-metallic parts. BACKGROUND OF THE INVENTION 10 Binders or systems of something were for cores and casting molds are well-known elements. In the casting technique, cores or molds for making metal castings are normally prepared from one more material in the form of aggregate particles, such as, for example, sand, and an amount of binder from a binder system. Organic and inorganic systems are presently employed as binders in the formation of products formed from a mixture containing a material in the form of particles such as, for example, sand. Typically, after mixing the particulate material and the binder, the resulting mixture is blended, blown or otherwise formed into the desired shape or patterns, and then cured with the use of catalyst and / or heat until reaching a been cured, solid. In the foundry industry, the binder typically represents from about 0.4 to about 1 /, by weight of the coated particle, such binder-coated melt particles have a particle size within a range corresponding to the numbers of Standard Test Sieve of the United States of America from 16 to approximately 270 (ie, a sieve aperture of 0.0469 inch to 0.0021 inch.) Typically, particulate substrates for use in smelting are granular refractory aggregates. include silica sand, chromite sand, zirconium sand, ovidin sand, etc., and mixtures thereof For purposes of the present invention, such materials are known as "sand" or "foundry sand". Regardless of the type of organic binder system, the organic binder used to produce the desired forms will volatilize hard cure and / or firing at metal pouring temperatures. Such processes produce smoke, olaroes, and additional unwanted and harmful emissions that may result in the need to comply with local and central government regulations. Another shortcoming of some organic binders systems is their relatively short bank life. To overcome the deficiencies of organic systems, some foundries employ inorganic binder systems. One type of inorganic binder widely used is an aqueous selection of a silicate, for example sodium silicate, ie water glass. (See U.S. Patent No. 4,226,277 which is incorporated herein by reference). The solution usually contains from 40 to 507 by weight of a sodium silicate having a weight ratio between Si02 and Na20 of 2.0: 1 to 3.2: 1. The North American patent Na. 4,504,314, which is incorporated herein by reference, presents the mixture of alkali metal silicate, lithosilated polyhydric alcohols, and optionally an oxyanion salt, with sand, and the resulting mixture is formed in a mold or core. After production, carbon dioxide gas is blown into the mold or core. Due to the chemical reaction between sadia silicate and carbon dioxide, an agglomerated core mold is formed. In another method, known as the self-casting silicate process (or the "non-cooking" process), described by Highfield et al, "The Mechanism, Control and Application of Self-Setting Sodium Silicate Binder Systems" (The mechanism, control and application of autofixed sodium silicate binders systems), AFS Transactians (1982) volume 99, pages 201-214 (which is incorporated herein by reference), the curing or hardening of the silicate form is achieved by the addition of organic esters as catalysts in the mixture of particles. U.S. Patent No. 4,416,694, which is incorporated herein by reference, has a foundry sand composition comprising particulate sand, aqueous sodium silicate co or binder and alkylene carbonate as a hardener. The North American patent Na. No. 4,983,218, which is incorporated herein by reference, presents aqueous alkali metal silicate solutions by the use of mixtures of alkylene carbonate and aliphatic alcohols, such as, for example, alkylene diols, polyalkylene glycols, or hydrauchiols. Although the binding properties of the silicates are generally satisfactory, when compared to organic systems they have a lower flowability of the binder / aggregate mixture due to the high viscosity of the silicate and the relatively high levels of binder required for a adequate resistance. In addition, when subjected to cast metal casting temperatures, the silicates tend to fuse making it difficult to remove the fused forms from the castings by mechanical shaking methods. The fused forms do not have any solubility in water either, which prevents their removal or dissolution by means of aqueous dispersion.

A second inorganic system, consisting of an aqueous solution of a polyphosphate glass, is presented in WO 92/06808 which is incorporated herein by reference. These agglomerates, when cured, exhibit satisfactory resistance, excellent rehydration, and the disaggregation of the aggregate pharmacy after exposure to metal melting temperatures. The deficiencies of this agglomeration system are include: limited resistance to humidity, softening of the aggregate system at high temperatures which limits its use in spherical alloy applications; and in comparison with the organic binders, a low flow capacity of the aggregate due to the relatively high levels of binder required to achieve adequate strengths. A third inorganic system is known, which consists of a larger portion of a finely divided refractory material mixed with a minor portion of a dry phosphate to which a minor portion of an aqueous alkali metal silicate is subsequently added in accordance with that indicated in U.S. Patent No. 2,895,838 (the entire disclosure of which is incorporated by reference) for making gas curable molds. This composition chemically reacts with a gaseous agent, bed for example carbon dioxide, to cure the composition by reacting the binder with an alkali metal carbonate formed by curing the inorganic system with carbon dioxide. Another known inorganic binder system, which includes a combination of silicate and palifasphate, is presented in the D.M. Kukuj et al., "Modification of Waterglass with Phosphorus Cantaining Inorganic Poly ers" (Modification of water glass with inorganic polymers containing phosphorus), (hereinafter "Kukuj et al", the complete presentation of which is incorporated herein by reference). The method of preparing this binder includes the processing of the silicate and the polyphasefacta at temperatures higher than the ambient temperature and at pressures higher than the ambient pressure in an autoclave to cause a chemical reaction of the inorganic polymers. The binder can be coated in sand and cured using C02 at ambient temperatures. In this work, only a low level of polyphosphate could be incorporated in the preparation of algomerante. In addition, Kukuj et al found that the maximum resistance system had only 5% polyphase modifier and that the resistance dropped dramatically when the binder contained more than 7V. of polyphosphate. Kukuj et al. Also found that small additions of polyphosphate in their binder (of about 1 to 3%) caused a dramatic increase in the viscosity of the binder before its addition to the aggregate. Thus, the shortcomings of this system include: high temperature processing and high pressure required to produce the laminar ag; formation of new chemical compounds with high viscosity; and low flow capacity of the agglomerating / aggregate system. Likewise, like U.S. Patent No. 2,895,838, the chemical interaction of the binder system with a gas containing carbon dioxide was necessary for the CUGAG system. SUMMARY OF THE INVENTION It is the main object of the invention to offer novel binder or substitute binder systems for organic and inorganic binder systems known in the prior art. The present inventors have carried out extensive studies on systems of 1 / o / phosph to / izadar and have achieved unexpected results in view of the results presented in U.S. Patent No. 2,895,838 and by Kukuj et al. The present inventors have learned that particular proportions of silica / soda are beneficial to achieve useful products. The present inventors have also learned that the use of certain catalysts in the prairie "na baking" process has superior flexibility to the process to achieve useful products such that the binder systems of the present invention are not limited to narrow proportions between silica and soda, nor narrow proportions between silicate and phosphate, but effective in a wide range of proportions. The novel inorganic agglomerating and aggregate systems are either fused or softened at high temperatures, for example SOO ^ C. Thus, they are useful with refractories and foundry sands used as molds to foundry cores in contact with molten metal, including ferrous metal casting processes. In addition, the binder systems of the present invention produce good strength properties in aggregate forms bonded to the binder of the invention. The present invention advantageously offers agglomerates for aggregate in order to obtain molds and cores that disintegrate with water even after exposure to a temperature of up to 1400 ° C, for example, exposure to a temperature within a range of 500 to 1200. ° C. The phosphates may be orthophosphates, candensate phosphates or mixtures thereof. The phosphates can also be processed in situ, in the presence of other ingredients, for example, silicate and / or aggregate, by the addition of a phosphoric acid and base, for example, sodium hydroxide, or converted from one phosphate to another. , in situ, by the addition of acid or base. An object of the present invention is to produce a binder system which once mixed with a particle material can be used to make useful shapes with satisfactory handling and processing properties. Another object of the present invention is to produce a agglomerating composition that contains silicate, phosphate and catalyst that can be cured by the "non-cooking" process. Another subject of the present invention is to produce a set of binder compositions containing catalyst, silicate and phosphate which, when mixed with a particulate material, can be used to prepare useful forms. Another object of the present invention is to produce a silicate binder system containing phosphates and catalyst for the casting of metals, for example ferrous metals. Another object of the present invention is to produce a silicate binder system containing phosphates and catalysts for non-ferrous and non-metallic castings. Another object of the present invention is to produce a set of binder compositions containing phosphate, silicate and catalyst for shaped aggregate objects having good shake or disintegration properties in water after exposure to molten metal melting temperatures for easy removal. of the formed piece. Other objects of the present invention are the provision of methods for making and methods for using the novel binder systems of the invention to overcome the problems related to the prior art and to form suitable useful cured objects. Contact surfaces of polymer and melted metal , including draft and injection molds, casting molds, cores and mandrels. These and other objects of the present invention will be apparent after taking into consideration the following description and the following examples. DETAILED DESCRIPTION OF THE INVENTION The inventors of the present invention have found that inorganic binder systems composed of silicates and phosphates are quite versatile enough to bond material in the form of a particle in the manufacture, for example, of cores, molds, mandrels, particle plates. , plastic compacts, partitions, and the agglomeration of other forms to produce forms that have a good resistance with an increased capacity of disintegration and solubility in water. The inventors have found that numerous variables in the inorganic binder system can be adjusted in such a way that a farmuladar can tailor a product to the needs of a customer. For example, formulating can easily adjust the relative amounts of silicate and phosphate in order to change the properties of a particular pharma. further, the farmuladar can use a specific phosphate or silicate to obtain the desired restil tates. In addition, the inventors may vary the working time of the inorganic aglamerant system by selecting a catalyst. The mechanical and moisture-wicking properties of the forms exposed to molten metal temperatures can be improved by using the binders of the invention instead of a binder containing 100% silicate. Furthermore, the present invention allows the use of phosphate, while a totally phosphate material would not even act as a binder in a non-cooking system. These results can be obtained, even with larger amounts of phosphate in the binder system than the amounts presented in US Pat. No. 2,895,838 or in Kukuj et al. SILICATES The silicates employed in the binders of the present invention may include the various alkali metal silicates including potassium, sodium and lithium. Other silicates, such as ammonium silicates can be used. In general, the silicates are available in the solution in aqueous solutions or in solids. In the present invention, the silicates, as a component of the binder of the invention, are preferably found in aqueous alkaline solutions characterized by a solids content of approximately 43% by weight unless otherwise specified. Soluble glass, Soluble glass, that is to say sodium silicate dissolved in water, which is the preferred alkali metal silicate used in the binder of the invention, can be characterized by the general formula xSi02 »and Na20. present invention intended for curing by means of the cooking process, the weight ratio between "x" and "and" ie between silica and sasa employed in the present invention is from 1.1: 1 to 3.85: 1, preferably from 1.6: 1 to 3.3: 1 and more preferably from 2.0: 1 to 2.7: 1. Lesser amounts of other camo elements such as alkaline earth metals, aluminum and the like may be present in various p. roparcians. The water content of the sodium silicate liquid can vary, depending on the properties, for example viscosity, desired by the end user. PHOSPHATES Phosphates used in the binders of the present invention include a salt of a phosphorus oxygen acid, including salts of phosphoric acids such as orthophosphoric acid, palpated fatty acid, pyraphosphonic acid, and ethaphosphoric acid. The phosphate used is selected from alkali metal phosphates and ammonium phosphates. Bed is employed in the specification and in the claims, the term "phosphate" is intended to be used in a generic sense to include both crystalline and amorphous inorganic phosphates, for example, sodium phosphate glass. In addition, phosphate includes, but is not limited to, ortafasphates and condensed phosphates. Orthophosphates are compounds that have a monotherapy tetrahebral ion unit (P04). Typical orthophosphates include sadia ortaphosphates, for example, monosodium phosphate, disodium phosphate or trisdicic phosphate, potassium ortaphases and ammonium orthophosphates. The condensed phosphates are compounds that have more than one phosphorus atom, and the phosphorus atoms are linked together. However, each phosphorus atom of the pair is directly attached to at least the same oxygen atom, for example, P-0-P. The general class of condensed phosphates in the present application includes linear polyphasfata, metafasfatas, pirafasfatos and ultrafosfatas. Metaphosphates are cyclic structures that include the ionic portion. { (F'03) n) n-, where n is at least 3, per axis pla, (Na3 (P03) 3). The ultrafasfates san condensed phosphates in which at least some of the tetrahedra of PO4 share 3 atoms of corner oxygen.

The pirafosfatas have an ion of (P2Q7), for example, Nan H4-n (P207) dande "n" is from 0 to 4. The linear polyphosphates have linear P-O-P chains and include an ionic portion of the general formula < (PQ3) nO), dande "n" is the length of the chain that ranges from 3 to several hundred, for example, 500, depending on the number of chain switches as an example, H2Q, present. A commercial palifasfata generally contains mixtures of linear palifasphatas and often also metafasphates and is characterized by an average chain length of at least 3, typically from 3 to about 45 and limited to 45 only by market demand, preferably the average is within a range of 3 to 32, with a preferred preference of 4 to 21. A preferred category of palifosphate is the category of amorphous candensate phosphates, for example, water-soluble phosphate glass. Taking into account the lessons learned, an expert in the field could produce mixtures of phosphates in accordance with the above defined and include even small amounts (up to 10%) of bed modifier ions for example, calcium, magnesium, zinc, aluminum, iron or boron in soluble phosphates and produce a phosphate encompassed within the present invention. In general, the phosphates are encompassed by the following Formula, for their molar ratio of oxide: (x MI + and M2 + z H2Q): P205, where MI is selected from the group consisting of L120, Na20, K20, and ( NH3) 2 • (H20) and mixtures thereof. M2 is optional and is selected within the rump consisting of CaO, MgO, FeO, Fe203, A1203, B203. The total oxide ratio R is equal to (x + y + z) mol / P205 poorly and is from about 0.5 to 3.0 or more, eg, 5. Typically, phosphates are characterized in accordance with the value of R according to as indicated in Table A.

Table i R Phosphate 0.2! R < 1 ultraphosphates R = l metaphosphates 1 < R < 2 polasphates R = 2 pyrophosphates 2 < R < 3 mixtures of phosphates R = 3 orthophosphates 3 > R phosphates plus metal oxides It will be noted that the phosphates can be added directly to the other ingredients, for example, added to silicates, or they can be created in situ with the other ingredients. The in situ creation can be achieved by half the use of acids, for example, any of the phosphoric acids, to bases, for example, alkaline hydroxides or oxides. For example, sadia phosphoric acid and hydroxide may be added together or they may be added sequentially to make a phosphate in situ with other binder ingredients. As will be apparent to a person skilled in the art from the reading of the present disclosure, the base hydroxide ions may be added, for example, supplied by added sodium hydroxide or provided by the silicate. The phosphates can be converted in situ to other phosphates by the addition of base or acid. For example, disodium phosphate can be converted to trisodium phosphate by adding sodium hydroxide, or converted to onosodium phosphate, by the addition of phosphoric acid. The phosphates can be used in a solid form or alternatively in aqueous solutions. The pH of the aqueous solutions can be acidic or alkaline. In the case of condensed phosphates, the pH is related to factors such as the length of the phosphate chain. CATALYST Several catalysts are found to cure particle samples mixed with the two-component silicate / phosphate binders. The catalysts include a catalyst selected from the group consisting of aliphatic carbonates, cyclic alkylene carbonates, aliphatic carboxylic acid esters, cyclic carboxylic acid esters, phosphate esters, and mixtures thereof. The aliphatic carbanates include those having the following Formula I: Rl-0- (C0) -0-R2 I, where R1 and R2 may be the same or different and are selected from (C1-C6) alkyl. The aliphatic carbanates preferably have from 3 to 7 carbon atoms such as, for example, dimethylcarbonate, diethylcarbonate, diprapyl carbonate or mixtures thereof. Cyclic alkylene carbonates include those having the following Formula II: where R3 and R4 are independently selected within the rump consisting of hydrogen and alkyl (Cl-CIO). Preferably, the cyclic carbonates include alkylene carbonate co or for example ethylene carbonate, propylene carbonate, butylene carbonate or mixtures thereof. In addition, typically, when an alkylene carbonate is employed, there may be absence of aliphatic alcohol. The esters of aliphatic carbaxyl acid are constituted by a portion of aliphatic carboxylic acid and a portion of aliphatic alcohol. The aliphatic carbaxyl acid moiety includes mannocarbaic acid having 20 carbon atoms, typical of 1 to 6 carbon atoms, and dicarboxylic acids having 2 to 20 carbon atoms, typically 2 to 6 atoms. of carbon. (In the present specification, the alkylaryl groups can be branched to either branched, as well as saturated or unsaturated.) The aliphatic alcohol moiety includes aliphatic alcohols, aliphatic palioles, ether alcohols and ether palory. The aliphatic alcohols are saturated to unsaturated alkyl alcohols having from 1 to 20 carbon atoms, typically from 1 to 6 carbon atoms. The aliphatic ether alcohols are saturated alcohols or unsaturated alcohols having the following Formula III (a): R5- (QR6) m-OH III (a), where R5 is a saturated to unsaturated alkyl portion having from 1 to 20 carbon atoms, typically of the 6 carbon atoms, each R6 is, independently, an alkyl portion having from 2 to 4 carbon atoms, linear or branched, and "m" is an integer from 1 to 8. Polys Aliphatics are saturated or unsaturated alkyls having from 2 to 20 carbon atoms, typically from 2 to 6 carbon atoms. Aliphatic ether folioles are saturated or unsaturated palioles having the following Formula III (b): R7- (0R8) -OH III (b), wherein R7 is a saturated or unsaturated alkyl portion having from 1 to 20 carbon atoms, typically from 1 to 6 carbon atoms, each R8 is independently an alkylene portion having from 2 to 4 carbon atoms, linear or branched, and "m" is an integer of ia 8, provided at least one of R7 or else R8 is hydraxy substituted in addition to the hydroxy group illustrated in Formula III (b). Typical aliphatic carboxylic acid esters include those of Formula IV (a): O (HO) a-Y (-0-C 8 -R9-H) b I (a), mere enter from 0 to 5, "b "is an entire number from 1 to 6, and R9 is alkylene (C1-C20). "Y" is saturated and has the Formula CcH2c-a-b + 2, dande "c" is an integer of 2 20, typically an integer from 2 to 6. The sum of "a" and "b" is a integer from 1 to a maximum of nares from a "c". For example, when "a" equals 1, "b" equals 2, "c" equals 3, "Y" is saturated, and R9 is CH2. 2O Formula IV (a) represents the following structure IV (b) and isomers thereof. Optionally, compounds of Formula IV (a) may include one or more ether groups of the formula (0R6) m between "Y" and the -OH or -0 (C0) R9H groups. Each R6 is, independently, an alkylene portion having 2 to 4 linear or branched carbon atoms and each "" is, independently, a whole number of ia 8. Examples of esters of Formula IV (a) also containing rumps ether include compounds having Formula IV (c): O (HO) a- - (0R6) -O-C-R -HI (c), where a, Y, R6, m and R9 are in accordance with that defined above . A suitable ester, which is not found within the Formula IV (a), includes compounds having the Formula V: 0 O II II R5- (0R) n-0-C-RIO-C-0- (R60) n-R5, each R5 and R6, independently, are defined camo above, n = 0 to 8, and RIO is a bond to alkylene (Cl-C18), typically C to C. Specific carboxylic acid esters employed in the present invention include dimethyl succinate, dimethyl glutarate, adiphate of dimethyl, monaacetin, diacenin, triacetin, ethylene glycol diacetate, and diethylene glycol diacetate. Esters of cyclic carboxylic acids are those of the following Formula VI: where "x" is equal to 2 to 10 and R12 and R13 are independently selected from the group consisting of hydrogen and (C1-C4) alkyl. The united repetitive units of Formula VII: ho have to be identical. Esters of physical cyclic carboxylic acids include propiolactane, butyrolactopa or caprolactone. Phosphate esters are those of the following Formula VIII: 0P (0R14) 3 VIII, wherein each R14 is independently selected from the group consisting of H, straight or branched (C1-C16) alkyl, -C6H5, -C6H4R15, dande R15 is straight or branched (C1-C12) alkyl and R16-C6H5, where R16 is straight-branched alkylene (Cl-C6), maximum bed two groups R14 are H. Preferably each R14 is methyl to ethyl. Generally, from about 5 to about 25% by weight of the binder is catalyst. For example, typical binders may include from about 8 to about 20. catalyst by weight of the aglamer. Preferably, from about 10 to about 18% by weight of the binder is catalyst PARTICLES The silicata / fasfata algamerant components can be used to mold aterial forms of water-insoluble particles of, for example, plastic, ceramic, wood and typically from a bed refractory material for example silica, zirconium, alumina, chromite, calcined clay, lightener, silicon, carbide, magnesite, dolomite, aluminum silicate, mulite, carbon, forsterite, chromium, magnesite and mixtures thereof. The mold, core or mandrel is produced from any of the sands identified above for forming products for use in foundry or other metal forming applications, for casting products for example cast iron, bronze, brass, aluminum and Other alloys and metals The molds, cores or mandrels of the present invention can also be used to form non-metals, for example plastics or ceramics. Molds, cores, and sand mandrels are well known to people with certain qualities in the ateria. AGGLOMERANT The amount of particular agglomerating comparators (silicate or phosphate component) and the total amount of binder used to create a shape, eg a mold bed, core or mandrel depends on the strength requirements as well as the shaking requirements and / o capacity of decomposition in water of the form. The total weight percentage of the binder, based on the weight of the particle material used to form a part, is defined by the amount of solids present in the binder components combined unless otherwise specified. In the present invention, the weight percentage of solid of the binder, based on the weight of the particulate material, is 0.4 to 5.0%, preferably 0.4 to 2.5%, and preferably 0.5 to 2.0%. The ratio of silicate to phosphate in the binder formed from a silicate component and a phosphate component of the present invention is from about 97.5: 2.5 to about 40:60, preferably from about 95: 5 to 60:40 apiraxically. ADDITIVES Aditives are used for special requirements. The 2.4 Binder systems of the present invention can include a wide variety of additional materials. Such materials include alkali hydroxides, for example, NaOH, water and various organic and inorganic additives. NaOH (45% -50% solutions, for example) may be present in the aglamer of the present invention in amounts of up to 10% to 40% by weight (solutions). Preferably, the aqueous binders of the present invention contain water in an amount of apraxically 40 to about 70% by weight of the total aqueous binder. Minor amounts of other additives such as for example surfactants may also be present. The surfactants can be anionic, ionic, cationic, amphoteric or mixtures thereof. Examples of water-soluble surfactants are anionic surfactants selected from organic sulphates, organic sulfonates and organic phosphate esters, such as, for example, potassium 2-ethyl hexyl phosphate. Some surfactants can operate camo flow control agents. A typical flow control agent includes an agent sold under the trademark PA 800K, more fully defined as potassium 2-ethylhexyl phosphate commercially available from LAKELAND LABORATORIES Ltd., Manchester, England. Other flow control agents include 2-ethylhexyl acid phosphate, DISPERSE-AYD W28, anionic / ionic surfactant sold by Daniel Products, Jersey City, NJ, USA, and DISPEX N40V, a sodium salt of a polyacrylate sold by Allied Callaids, Suffal, VA, USA. Other additives include moisture resistant additives, actual decomposition standards, preservatives, colorants, bulking agents, thermal resistance additives or flow enhancers. Moisture resistant additives include potassium tetraborate, zinc carbonate, zinc oxide. Clearance enhancers include sugar, for example sucrose, dextrose and acerrin. Other additives include mold release agents, adhesion promoters, couplers and employ- ers, metal pouring improvement additives, for example, pit pit oxide, black iron oxide, clay, etc. Refractory linings can be used to improve the finish of the castings. Obviously, the additives can be added in combination to biep in a unitary manner. MIXING THE AGGLOMERANT AND PARTICLES In general, a sufficient amount of catalyst is mixed to cure a agglomerant to a foundry aggregate. Then, the phosphate and silicate binder components are added simultaneously or separately to the aggregate / catalyst mixture. Thus, one approach is the mixture of aqueous phosphate with the aggregate / casting catalyst mixture and then the mixing of the alkaline aqueous sodium silicate solution having an appropriate proportion between silica and soda with the foundry aggregate / catalyst mixture. izadar / fasfata. A flow agent is optionally added at any time during mixing. The resulting mixture is formed and then self-cured to form a shaped product, for example, sand-to-mold core. Alternatively, a solid phosphate component can be included in the particle, said component is first mixed with water, and then an aqueous alkaline solution of sadium silicate is added. This composition is mixed completely. The catalyst can be mixed at any stage of the preparation of this mixture. However, preferably, it is added before the silicate solution. In a further alternative, the phosphate and silica components can be premixed together to form an aqueous solution and stored in this condition before being added to the sand. In battlements some modalities, the pre-mixed solution is a clear (transparent) mixture at least before its. mix can added. The curing catalyst must be added to the aqueous solution simultaneously, just before mixing or just after mixing the pre-mixed solution with the aggregate. In another alternative, the silicate, phosphate and aggregate components can be mixed dry and stored in this condition. When they are ready, water and catalyst can be added to this dry mix. In alternative atra, the silicate, phosphate and dry catalyst, for example, ethylene carbonate, can be dry mixed and stored in this condition. When they are ready, you can mix water and added to this dry mix. As an alternative to the separate phosphate bed ingredient supply, the phosphate can be formed in situ by the addition of phosphoric acid and a base as binder ingredients before or after the aggregate or silicate mixture. In addition, the phosphate in the binder can be changed to a different phosphate in situ by the addition of acid to base. The procedure for mixing aglamerant with water insoluble particles may include modification, if necessary, of the proportion between silica and soda of sodium silicate with an alkaline substance. After mixing the binder and the particles, the mixture is loaded in a pattern to obtain a shape and the form is cured. Generally, the curing is carried out by the action of the catalyst to protect the environment. However, the formed mixture can be heated, if desired, to assist curing. When the mixture is to be cured in accordance with "baking" procedures, the mixture of catalyst, particulate material and binder is formed and allowed to cure simply. This forms a product such as a casting core or mold. The particulate material coated for. its use in a foundry comprises a sand particle and a resin coating. The particle in the cttal is applied, the resin has a pre-coated size within the range of Standard Test sieves of the United States of America from about 16 to about 270, preferably from about 30 to about 110. The compositions of ag of this invention can be mixed with a wide range of particulate materials. At least, a binder amount of the binder compaction must be present to coat the sand particles and to provide a uniform mixture of sand and binder. Thus, a sufficient amount of aglamerant is present in such a way that, when the mixture has the desired pharmacy and is cured, a shaped, uniform, resistant, substantially uniformly cured article is provided throughout its extension, thus minimizing breaks and deformations. during the handling of the article formed as eg sand molds or sand cores made from this pharma. As used in the specification and in the claims, the term "mold" refers to a "?"? generic sense to foundry forms that include molds and cores, this invention is in no way limited to the former. In addition, the term "mold" includes various patterns for use in the molding technique including molds for setting and injection as well as bedding molds including shell mold forming elements in addition to a complete shell mold structure prepared by the mold. assembly of two or more supple thin-walled shell olde elements. Accordingly, it will be noted that the term "mold" is used to include a surface that defines a shape or a cast, in general terms, and specifically encompasses molds, cores and mandrels. The invention may also be illustrated with reference to the limitative examples presented below: The inventors have found that dog bones prepared by the two silicate / phosphate binders system can also be successfully cured by the cooking process using catalysts that are added to the sand / binder mixtures in amounts up to about 25. % by weight based on the weight of the binder. The methods are described below "COMPARATIVE EXAMPLE I AND EXAMPLES 1-2 The binder system used in these experiments > it comprises a sodium silicate liquid (ratio between Si02 to Na20 of 2.58 with 44.5% solids) and a 45% by weight solution of sodium palifosphate (BUDIT 4, with an average chain length of 32). These liquid components were premixed in a panderal proportion of 83.3 to 16.7 in weight, before use. This binder was used in the examples of the present invention illustrated in Tables 2 and 3. 3000 gm of WEDRON 530 silica sand in a Hobart mixing vessel. 10.5 gm of catalyst (10% by weight, based on the weight of the aglamerant) were added to the sand and mixed for 1 minute. Such a catalyst included diacstine (glyceryl diacetate), triacetin (glyceryl triacetate), and dibasic acid esters sold by DuPont under the name of DBE-9 (a mixture of dimethyl succinate, glutarate and adipate). Then 105 g of the prepared binder was added and mixed for an additional 2 minutes. After mixing, the resin-coated sand was manually packed into two 12-cavity core boxes to make the dog bones. A plastic sheet was used to cover the core boxes to avoid surface drying of the sand mixture. The superficial hardness of the bitch's bones was monitored to determine the bench life and the time of removal. The bench life is the time available, after mixing the catalyst and the binder with the sand for the operator to prepare the pharma. After this time, the reaction between the catalyst and the binder has advanced too much so that a useful agglomeration of the sand can be performed. The time of removal is the time in which the pharma has reached enough resistance to be able to be removed from the mold (pattern) without risk of rupture or distortion of the formed object. In Examples 1-2 and Comparative Example i, the time required for the dog bones to reach a surface hardness of 5 psi was defined as bed life of the coated resin resin bed and the time necessary for the bones of dog reach a surface hardness of 25 psi bed was defined the time of removal. After the time of removal was over, the bones of the bitch were removed. The tensile strength of the dog bones was then determined at 4 hours and 24 hours, unless otherwise specified, after preparation of the coated sand. All tensile strength measurements were made with a ZGII-XS electronic tensile strength tester (Thwing-albert Instrument Company, Philadelphia, PA). The properties of Tensile strength are critical for the development of a commercial binder system. It is essential that the cores and molds made with these binders have sufficient strength for handling during the processing and handling of core and mold. The compressive strength was determined after subjecting the dog bones to a temperature of 925 ° C for 15 minutes and after cooling for 1 hour. The results reported in Table 2 were compared with dog bones prepared with a 100% silicate binder system cured also with the ester. The parameters of the bench life and removal time in Table 2 show that the change in the catalyst affects the curing speed. Table 2 shows that the tensile strengths of the phosphate modified systems of Examples 1 and 2 are weaker than the unmodified sodium silicate system of Comparative Example 1. Table 2 also shows that the phosphate modified systems they have better shaking properties (disintegration capacity) than the unmodified sodium silicate system in accordance with what is indicated by the much lower compressive strength.

TABLE 2 Diacetin, Triacetin and Esters of Acid Dibasic Ca Bed to Oxygen Mixtures of Diacetin Acid Esters and Triacetin - to Dibasic - b Example No. Exemplifies Example Example 2 parative 1 1 Sodium silicate 100 83.3 83..3 SiO2 / Na20 ratio, 2.58 O Palifosphate 16.7 16.7 salt, n = 32 Bench life 31.5 > 1 0 > 360 (min,) Time 59.5 169 > 360 removal (min.) Resistance to 85 51 ND-c traction (psi), 4 hours Resistance to 198 83 92-d traction (psi), 24 hours Resistance to 375 < 50 ND-c Compression (psi) after exposure to 925 ° C 3. The catalyst consisted of mixtures of 15% diacetin and 85% triacetin (by weight). b. DBE-9 bed dibasic acid ester sample was obtained from E.I. DuPont de Neumours & Ca., Wilmingtan, Delaware, USA. c. ND is defined as not determined. d. The dog bones were removed from the box after 3 hours.

EXAMPLE 3 AND COMPARATIVE EXAMPLE 2 3000 gm of WEDRON 530 silica sand was placed in a Hobart mixing vessel. 10.5 gm of prapylene carbonate catabolizer (10% by weight based on the weight of the binder) were added to the sand and mixed for 1 minute. Then, 105 gm of combination binder, prepared in accordance with the procedure of Example 1, will be added and mixed for an additional 2 minutes. After this, the mixture was manually packed into 2 12-well core boxes to make bitch bones. A plastic sheet was used to cover the core box to prevent surface drying of the sand mixture. The superficial hardness of the bones of the bitch was monitored. The bank life and the time of removal according to the above described were determined. The tensile strength of dog bones was determined at 2 and 24 hours after mixing the binder with the sand. The compressive strength was also determined after the dog bones at a temperature of 925 ° C for 15 minutes and cooled for 1 hour. The results reported in Table 3 were compared with dog bones prepared with a 100% silicate aglamerant system also cured with carbonate.

TABLE 3 Pratilena Carbonata coma Catalyst Example No. Example Exemplary 3 Comparative 2 Silicato de sadio, proportion 100% by weight 8.3% by weight Si02 / Na20, 2.58 Pol ifasfato de sodio, n = 32 0 16.7% by weight Bench life (min) 5.5 8 Reclamation time (min) '12 18 Tensile strength 76 70 (psi), 2 hours Tensile strength 156 112 (psi), 24 hours Resistance to compression 300 < 50 (psi) after exposure to 925 ° C EXAMPLES 4-12 These samples evaluated catalyst bed, four esters and a carbonate added at 10% by weight based on the resin. The catalysts and pleated were mixtures of ethylene glycol diacetate (EGDA), diacetin (DA), triacetin (TA), propylene carbonate (PC), and a mixture of dibasic acid esters (DBE) (33% dimethyl succinate, 66% dimethyl glutarate, and 1% dimethyl adipats, available in RhSne-Poulenc Basic, chemicals, Staveley, Reipo Unido). The sand used was C0NGLET0N 60, manufactured by Hepwarth Limited, Bir ingham, England. The binder was blended with SB41 (sodium silicate, 42% solids, with a silica to soda ratio of 2.65, available from Crosfield Chemicals, Warripgtan, England), deionized water, BUDIT 7 (sodium polyasphate with an average chain length of 16, available from K &K Greeff, Manchester, England), and PA800K (potassium 2-ethylhexyl phosphate, used bed flow control agent, and available from Lakeland Laboratories Ltd., Manchester, England). The liquid resin was present in an amount of 3% based on the weight of the sand. The test procedure was as follows. A combination aglamer was prepared by mixing 70. part (in weight) of SB41 (a silicate of sadia that has a ratio between silica and soda of 2.65 and 42.3% solid) with 16.5 parts (by weight) of deionized water. In this solution, 13.5 parts (by weight) of BUDIT 7 were dissolved and finally 0.8 parts (by weight) of PA800K were added and mixed to form a homagnea solution. This binder was used in the examples of Table 4 and 5. 2500 gm of C0NGLET0N 60 sand was weighed into the mixing vessel of a Kenwood Chef mixer. The temperature of the sand was adjusted to 20 ° C by dry mixtures to well addition of cold sand. The required amount of catalyst (10% by weight of the resin) was weighed into a cup and then transferred to the sand. The cup was then rinsed with 3 portions of sand to ensure that all the catalyst had been transferred to the vessel. The catalyst was mixed with the sand for 1 minute in order to ensure a homogeneous mixture of sand and catalyze. The resin was weighed in a disposable 50 ml plastic syringe. Can the mixer working, the resin was injected into the sand / catalyst mixture in a period of 10 seconds. The speed of the mixer was increased to a maximum (300 revolutions per minute) for 30 seconds. The coated sand was discharged and used to determine the bench life and the reaction time and to prepare samples for flexural strength measurements. These measurements were determined at a temperature of 20 ° C. In the Exemplars of Tables 4, 5, 6 and 7, the bench life and the removal time were measured by a procedure slightly different from the procedure used in the examples in Tables 2 and 3. Regarding the measurements of the Bench life and time of removal, coated sand was packed in a plastic tube (10-12 cm deep and 12-15 cm in diameter). The surface hardness of the sand packed in the plastic tube was manipulated periodically using a Risdale Dietert scratch hardness tester. When the surface hardness of the packed sand reached three units of scratch hardness, the time (from the time in which the resin was added) was recorded as bank time. The surface hardness measurement continued until a consistent surface hardness reading of more than 50 was obtained. The partially cured packed mixture was immediately removed from the tub. The surface hardness on the underside of the packed sand was tested to obtain a consistent surface hardness reading greater than 50. Time (from the time the resin was added) was recorded as the removal time. In the case of bending resistance measurements, at the same time as the plastic tub was packed for bench life measurements and removal time, the coated sand was manually packed in a calibration box that provided samples with a dimension of 18 c, 2.25 cm and 2.25 cm. After the removal time was determined, the separated pieces for bending resistance measurements were removed from the calibration box. Two samples were measured to determine the flexural strength, at 1 hour, 2 hours and 25 hours after the removal using a tensometer supplied by TC, Howden, Leaminton Spa, England and equipped with jaws with a reach of 15 cm . Table 4 shows several mixtures of catalysts that provide removal times of 12.5 to 32 minutes. All bending resistance results are an average of two values, unless otherwise indicated. Table 4 presents a list of the percentage composition by weight of the catalyst part of the binder.

TABLE 4 Example No. 4 Diacetin (% by weight) 40 Triacetin (% by weight) 60 Carbonate of prapilene 80 60 40 (% by weight) EGDA (% by weight) 0 4 60 DBE (% by weight) Bench life (minute) 17 7.5 Removal time (minute) 32 12.5 15.5 19 Flexural strength 7.7 10.9 9.1 7.8 (a) 1 hour (kg / cm2) Flexural strength at 14.5 14.1 11.4 il.4 (b) 2 hours (kg / cm2) Flexural strength at 21.3 20.9 19.1 2i.6 (b) 24 hours (kg / cm2) TABLE 4 (cantinaution) Example Na. 8 9 10 11 12 Diacetin (% by weight) - - - - - Triac tina (% by weight) - - - 20 40 Carbonate of prapilena 85 70 55 80 60 (% by weight) EGDA (% by weight) - _ __ _ _ DBE (% by weight) 15 30 45 - - Bank life (minute) 6 7 10 6. 5 8 Removal time (minute) 14 15 17 13 16 Resistance to bending at 12.7 (2 hr) 12.7 7.3 6.4 8.6 1 hour (kg / cm2) Resistance to bending at 13.6 (3 hr) 11.4 10.4 10.0 15.4 2 hours (kg / cm2) Flexural strength at 19.1 23.2 23.6 20.4 19.5 24 hours (kq / cm2) (a), average of 4 measurements (b). average of 6 measurements EXAMPLES 13-18 Using the binder prepared according to Examples 4-12 above at a level of 3% by weight based on the weight of the sand and with the ester compositions of Table 5 at a level of 10% based on To the weight of the resin, the effect of varying the mixtures of diacetin ester and triacetin on banking life and the time of removal in a system was determined and recorded in Table 5. Table 5 presents a list of the percentage composition by weight of the catalyst portion of the binder.

TABLE 5 Exemplary No. 13 14 15 16 17 18 Diacetin (% by weight) 75 60 50 35 25 18 Triacetin (% by weight) 25 40 50 65 70 82 Banking life (minute) 3 7.5 11.5 17.5 58 93 Removal time (minutes) 9 16.5 24.5 52 85 165 From all the above datas, it is apparent that a system has been provided which has various bank life properties and time of removal that can be adapted for specific uses. Table 2 and Table 3 further show that they have improved shake properties after exposure of the formed card at 925 ° C. EXAMPLES 19-24 AND COMPARATIVE EXAMPLE 3 Examples 19-24 and Comparative Example 3 study the effects of changing the ratio between sodium silicate and sodium phosphate. In these Examples, sodium phosphate was first dissolved in deionized water to form a 45% by weight solution. This solution was then mixed in the appropriate proportions with the sadia silicate solution (as shown in Table 6). This resulting binder was then added to the mixture of sand and catalyst. The sand coated with aglamerant was then tested for bench life, time of removal, resistance to bending and water softening in accordance with what is reported in Table 6.

TABLE 6 Example No. 19 20 21 22 Si Sodium Icate - at 75 70 65 60 Polyphosphate solution 25 30 35 40 sodium - b Bench life (min) 5.0-c 5. 5.5-c 5.5 Removal time (min. ) 12.3-c 13.0 12.5-c 12.5 Resistance to flexion (kg / cm2) 1 hour 8.8-d 7"3 4.1 5 2 hours 9.5-e 9.1 6.4 6.4-f 24 hours 21.3 20 19.1 20.9 Softening in gua 91 46 41 34 (second) - h TABLE 6 (continued) Ex emp 1o No. 23 24 Exemplary Campaign 3 Sodium silcata - a 55 50 100 Palifosphate solution 45 50 0 sodium - b Banking life (min) 7.3-c 7.5 Removal time (min) 18.0-c 18.0 11 Resistance to flexion (kg / cm2) 1 hour 3.6 2 .7 9.1- • g 2 hours 2.7 3 10.9 24 hours 21.8 13 16.8 Softening in gua 16 ND greater than (second) - h 600 Notes: a. The sodium silicate was SB41. The addition of total liquid binder (silicate and phosphate) was 2.25% based on the weight of the sand and the addition of pragile carbonate was 13.33% based on the resin. b. The sodium palifosphate was BUDIT 7 with an average chain length of 16. BUDIT 7 was dissolved in deionized water to provide a 45% solution in weight, before of use. c. Average of two experiments. d. The flexural strengths were measured 2 hours after sample preparation. and. The flexi? P resistances were measured 3 hours after sample preparation. F. The flexural strengths were measured 2.5 hours after sample preparation. g «The flexural strengths were measured 1.5 hours after sample preparation. h. The softening in water of a sample heated to 925 ° C for 15 minutes was measured and then cooled to room temperature. ND means not determined.

For the evaluation of the softening in water, the broken sample obtained from the measurement of flexural strength was heated during 15 minutes in an oven maintained at a temperature of 95 ° C. After cooling, a piece of each sample was placed in water at 20 ° C in a petri dish such that the water level was about i / 3-1 / 4 of the sample. The surface was continually abraded by abrasion with a metal spatula until 2 mm surface softens. The time was measured and a water softening measurement was reported in Table 6.

In addition to the data in Table 6, the cold portions of the thermally treated samples not used for softening in water were evaluated to determine the physical resistance by simple hand pressure. All were extremely weak in such a way that no mechanical measurement could be carried out. Using this subjective test, all samples were very similar except Comparative Example 3; the silicate standard was much harder than the other samples. EXAMPLES 25-29 Examples 25-29 determine the effect of changing the ratio between Si02 to Na20 of the sodium silicate. For these examples, the procedure of examples 19-24 described above was repeated. However, sand tests were carried out with a binder system of 70% by weight of sodium silicate and 30% by weight of BUDIT 7. The sodium silicate with different proportions of SiO 2 and NaO 2 was prepared by the addition of an appropriate amount of a 45% by weight sadia hydroxide solution to SB41. The addition of binder was 2.25% based on the weight of the sand and the addition of propylene carbonate was 13.33% based on the weight of the resin. The resulting bench life, removal time, resistance to bending and softening in water measured for the prepared samples are shown in Table 7.

TABLE 7 Example Ho. 25 26 27 28 29 Proportion between Si02 and 2.65 2.3 2 1.7 1.4 Na02 of sadia silicate Bench life (min) 6-a 10.5 10.8-b 11 14.8-a Removal time (min) 14.5-a 15 17.5-b 17 31.0-a Flexural strength (kg / cm2) 1 hour 4.1 6.8-b 10.4 6.4 2.7 2 hours 6.4 10.4 9.1 10 4.5 24 hours 19.1 20.4 18.2 20.9 20.9 Softening in water 44 111 112 If 90 (seconds) - c to. Average of 2 experiments. b. Flexural strengths determined 1.5 haras after sample preparation. c. Softening in water measured in a sample heated to 925 ° C for 15 minutes and then cooled to room temperature.

The data in Table 7 show that the increasing alkalinity of the silicate increases working times without sigificatively influencing flexural strength at 24 hours. While the invention has been described in combination with the specific embodiments thereof and with reference to the Tables presented herein, it is evident that many of the errors, modifications and variations will be apparent to those skilled in the art based on the foregoing description. For example, the methods of the invention may include heating by heating lamp to re-water and / or to accelerate the curing speed. Dehydration of the malde can also be used during curing by contacting the mold with air in displacement. Dehydration in vacuum can also be used. However, it will be understood. that, for the purposes of this specification, the air is considered inert gas bed and may be replaced by any other inert gas coma, eg, nitrogen, argon, etc. or mixtures of inert gases. The temperature of the air or other inert gas is such that dehydration is achieved and adequate results have been achieved at a temperature ranging from ambient temperature to a temperature of 90 ° C and above. A vacuum support can be used alone or can be used in combination with the other modalities to facilitate dehydration. Accordingly, the purpose is that the present invention includes all of these alternatives, modifications and variations that are within the spirit and scope of the appended claims.

Claims (49)

1. CLAIMS i. A binder composition comprising: a mixture of a silicate, a phosphate and a catalyst selected from the group consisting of aliphatic carbonates, cyclic alkylene carbanates, esters of aliphatic carboxylic acids, esters of cyclic carboxylic acids, phosphates esters and mixtures thereof.
2. 2. The composition of claim 1, wherein the catalyst comprises at least one aliphatic carbonate having the formula I: Rl-0- (C0) -0-R2 I, dande Rl and R2 may be identical or different and are selected inters (C1-C6) alkyl. The composition of claim 1, wherein the catalyst comprises at least one cyclic alkylene carbonate having the formula II:
3. where R3 and R4 are independently selected from the group consisting of hydrogen and (C1-C10) alkyl.
4. 4. The composition of claim 1, wherein the catalyst is selected from the group consisting of ethylene carbonate, propylene carbonate, butylene carbonate, and mixtures thereof.
5. 5. The composition of claim 1, which comprises the aliphatic carboxylic acid esters of the aliphatic carboxylic acid esters, is the product of the reaction of an aliphatic carboxylic acid moiety and an aliphatic alcohol moiety, the of aliphatic carbaxyl acid is selected from mancarbaxylic acid of 1 to 20 carbon atoms and dicarbaximic acid of 2 to 20 carbon atoms, the aliphatic portion being selected from the group consisting of aliphatic alcohols having from 1 to 20 carbon atoms, aliphatic palyols having from i "to 20 carbon atoms, ether alcohols of the formula III (a): R5- (0R6) m-0H III (a), where R5 is a saturated or unsaturated alkyl moiety having 20 carbon atoms, each R6 is independently an alkylene portion having 2 to 4 carbon atoms, and "m" is an integer from 1 to 8, and ether palilels of the formula III (b) : R7- (OR 8) m-OH III (b), where R7 is a saturated or unsaturated alkyl moiety having from 20 carbon atoms, each R8 is independent in te an alkylene portion having from 2 to 4 carbon atoms and "is in accordance with that defined in formula III (a), provided that at least one of R7 or R8 is hydroxy substituted in addition to the hydroxy group and shown in formula III (b).
6. The composition of claim 5, wherein the catalyst comprises at least one aliphatic carboxylic acid ester having the formula IV (a); OR
7. II (HO) -Y-f-0-C-R9-H) b IV (a), dande "a" is an integer from 0 to 5, "b" is an integer of l 6, R9 is alkylene (C1-C20), and Y is CcH2c-a-b + 2, where "c" is an integer from 2 to 20, the sum of "a" and "b" is maximum 6, optionally at least an -OH group of the formula IV (a) is attached to Y through an ether group of the formula (0R6) m, and optionally at least one group - (0-C (Q) -R9-H) of the Formula IV (a) is linked to Y through another ether group of the formula (0R6) m, where each R6 is independently an alkyl portion having from 2 to 4 carbon atoms and each "m" is independently an integer of ia
8. 8. The composition of claim 6, wherein the catalyst comprises at least one carboxylic acid ester having the formula IV (c): O

   II (H0) aY- (0R6) m-0-C-R9-H IV (c), where "a" is an integer from 0 to 5, each R6 is independently an alkylene portion which has 2 to 4 carbon atoms, Y is CcH2c-a + l- where "c" is an integer from 2 to 20, "" is an integer from 1 to 8, and R9 is alkylene (C1-C20). The composition of claim 5, wherein the catalyst comprises at least one carboxylic acid ester having a formula V: OO R5- (0R) n-0-C 11 -R10-C I-0- (60) n -R5, wherein each R5 and R6 are independently in accordance with that defined in formula III (a), n = 0 to 8, and RIO is a bond or alkylene (C1-C18).
9. 9. The compassion of claim 1, wherein the catalyst comprises at least one cyclic carboxylic acid ester having a formula VI:

   -r = 0 Rl3 ^ C > # SAW. where "x" represents 2 to 10 and R12 and R13 can be independently selected from the group consisting of H and (C1-C4) alkyl and mixtures thereof.
10. 10. The composition of claim 1, wherein the catalyst comprises at least one phosphate ester having a formula VIII: 0P (0R14) 3 VIII, each R14 is independently selected within the 5 ^.
11. group consisting of H, straight or branched alkyl (Cl-C16), -C6H5, -C6H4R15, dande R15 is straight to branched (C1-C12) alkyl, and -R16-C6H5, where R16 is (C1-C6) alkylene linear or branched, maximum bed two groups R14 are H. il. The composition of claim 1, wherein the catalyst is selected from the group consisting of di-ethyl succinate, dimethyl glutarate, dimethyl adipate, prapiolactan, butyralactone, capralactone, onaacetin, diacetin, triacetin, ethylene glycal diacetate, diethylene glycol diacetate. and mixtures thereof.
12. 12. The composition of claim 1, wherein the catalyst is present in amounts of about 5 to 25% by weight based on the weight of the binder.
13. 13. A composition for processing particles of particulate material, comprising the binder of claim 1, and particulate material.
14. 14. The compassion of claim 13, wherein the particulate material is sand, and the sand is present in amounts of 95 to 99.6% by weight based on the total weight of the compassion.
15. 15. The composition of claim 1, wherein the silicate is less a silicate selected within the group consisting of alkali metal silicates and ammonium silicates.
16. 16. The composition of claim 1, wherein the silicate has a ratio between SiO2 and Na20 of 1.1: 1 to 3.85: 1.
17. 17. The composition of claim 1, wherein the silicate has a ratio between Si02 and Na20 within a range of 2.0: 1 to 2.7: 1.
18. The composition of claim 1, wherein the phosphate is at least one phosphate selected from the group comprising alkali metal phosphates and ammonia phosphates.
19. 19. The composition of claim 1, wherein the silicate comprises sadium silicate and the phosphate is at the epos a selected palphosphate within the rump consisting of sadium pslifasphate and potassium polyphasphate.
20. 20. The composition of claim 1, wherein the phosphate component of the binder has an ionic portion of formula ((P03) n0) 3 where "n" is an average chain length of 1 to 32.
21. 21. The composition of the Claim 1, wherein the phosphate component of the binder is a sadia palifosphate.
22. The composition of claim 1, wherein the phosphate is a polyphosphate having an ionic portion of the formula ((P03) n0) dande "n" is an average chain length and ss is between 3 and 32, including these values .
23. 23. The composition of claim 1, further comprising a surfactant.
24. The compassion of claim 1, further comprising a water-soluble anionic surfactant selected within the rump consisting of organic sulphates, organic sulfonates, organic phosphate esters and mixtures thereof.
25. 25. The compassion of claim i, wherein the ratio between silicate and phosphate is about

    97. 5: 2.5 Approximately 40:60 in weight based on solids.
26. 26. The composition of claim 1, wherein the ratio between silicate and phosphate is from about 95: 5 to 60:40 by weight based on the solids.
27. 27. A system comprising a dry silicate component, a secs phosphate component, and a catalyst selected from the group consisting of aliphatic carbonates, cyclic alkylene carbonates, esters of aliphatic carbaxyl acids, esters of cyclic carbaxyl esters, esters of phosphate and mixtures thereof.
28. 28. A method for making a binder that encase the mixture of a silicate, a phosphate, and a selected catalyst within the group consisting of aliphatic carbonates, cyclic alkylene carbonates, esters of aliphatic carboxylic acids, esters of cyclic carbaxyl acids, phosphate esters and mixtures thereof.
29. 29. The method of claim 28, wherein the catalyst is at least one selected catalyst within the rump consisting of (A) alkylene carbonates of the formula I: Rl-0- (C0) -0-R2 I, R1 dande and R2 may be the same or different and are selected from (C1-C6) alkyl, (B) cyclic organic carbonates of the formula II,

    wherein R3 and R4 are independently selected from the group consisting of hydrogen and (C2-C10) alkyl, (C) esters of aliphatic carboxylic acids, wherein the esters of aliphatic carbaxyl acids are the product of the reaction of a carboxylic acid moiety aliphatic and a portion of aliphatic alcohol, a portion of aliphatic carboxylic acid is selected from monocarboxylic acids having from 1 to 20 carbon atoms and dicarboxylic acids having from 2 to 20 carbon atoms, the aliphatic portion being selected from the a group consisting of aliphatic alcohols having from 1 to 20 carbon atoms, aliphatic polyols having from 1 to 20 carbon atoms, ether alcohols of the formula III (a): R5- (0R6) m-0H III (a ), R3 is a saturated or unsaturated alkyl portion having 1 to 20 carbon atoms, each R6 is independently an alkylene portion having 2 to 4 carbon atoms, and "m" is an whole number from 1 to 8, and palióles ether of formula III (b): R7- (0R8) m-0H III < b), wherein R7 is a saturated or unsaturated alkyl moiety having from 20 carbon atoms, each R8 is independently an alkylene moiety having from 2 to 4 carbon atoms and "in" is in accordance with that defined in the formula III (a), provided that at least one of R7 or R8 is hydroxy substituted in addition to the hydroxy group shown in formula III (b), (D) cyclic carboxylic acid ester of formula VI:

    where "x" is equal to 2 to 10, R12 and R13 can be independently selected from the group consisting of H and (C1-C4) alkyl and mixtures thereof; and (E) phosphate esters having a formula VIII: 0P (0R14) 3 VIII, wherein each R14 is independently selected from the group that wears from H, to either branched (C1-C16) alkyl, C6H5, C6H4R15, where R15 is straight or branched (C1-C12) alkyl, and -R16-C6H5, where R16 is straight or branched (C1-C6) alkylene, at most R14 groups are H.
30. 30. The method of claim 28, wherein the catalyst is selected from the group consisting of dimethyl succinate, dimethyl glutarate, and dimethyl adipate, propiolactan, butylactone, caprolactan, onaacetin, diacetin, triacetin, ethylene glycol diacetate, diethylene glycol diacetate, and mixtures thereof.
31. 31. The method of claim 28, wherein the catalyst is selected within the rump consisting of ethylene carbonate, propylene carbonate, butylene carbonate, and mixtures thereof.
32. 32. A method for joining particulate materials with a binder, comprising: supplying the composition of claim 13; shape the composition; and allow the healing of compassion.
33. The method of claim 32, wherein said step of supplying the composition comprises the addition of at least one of said silicates, at least one of said phosphates, and at least one of said catalysts to the particulate material to form the composition .
34. 34. The method of claim 33, wherein the silicate and phosphate are added to the particulate material before the addition of the catalyst.
35. 35. The method of claim 33, further comprising adding water to the particulate material to form an aqueous mixture, the particulate material is foundry sand, the silicate is a sadium silicate, and the silicate Sadia and phosphate are added to the aqueous mixture.
36. 36. The method of claim 32, wherein the shaping step comprises charging the mixture in a pattern.
37. 37. The method of claim 32, wherein the delivery of the composition comprises the in situ formation of the phosphate.
38. 38. The method of claim 37, wherein the in situ formation comprises contacting a phosphoric acid with a base.
39. 39. The method of claim 37, wherein the in situ formation comprises contacting a phosphate precursor with a member of the group consisting of an acid and a base to form the phosphate in situ.
40. 40. The method of claim 32, wherein the composition is an aqueous composition and is pharmaceutically mixed by mixing the particulate material, the silicate, the phosphate, and the water.
41. 41. A mold that can disintegrate in water, which catches, a mass of particles; formed, the individual particles of the mass are bonded together with a binder comprising at least one water-soluble silicate and at least one water-soluble phosphate, and at least one catalyst selected from the group consisting of aliphatic carbonates, cyclic organic carbonates , esters of aliphatic carboxylic acids, esters of cyclic .carbaxylic acids, phosphate esters and mixtures thereof, the resulting binder is soluble in water.
42. 42. The mold of claim 41, wherein the mold can disintegrate in water after exposure to a temperature within a range of 500 ° to 1400 ° C.
43. 43. The mold of claim 41, wherein the particles are laminated from at least one material selected from the group consisting of silica, alumina, silicon carbide, magnesite, dolomite, aluminum silicate, mulite, carbon, farsterite, mineral chrome-magnesite, zircania, clay, chromite, calcined clay and relieves.
44. 44. The mold of claim 41, wherein the binder provides the mold with shake drying properties.
45. 45. The mold of claim 41, wherein said phosphate has "n" number of phosphate units ((P03) n0) where "n" is a numerical average of 3 to 32, including these values.
46. 46. The mold of claim 45, wherein "n" is from 4 to 21, including these values.
47. 47. The mold of claim 45, wherein no isamorphic replacement of silicate isnes with phosphate isnes prior to mixing the sand with the binder.
48. 48. A method for making a molded metal product comprising supplying a mold according to claim 41 and casting a molten metal against said mold.
49. 49. A method for joining particulate materials with a binder, the method comprising: supplying an aqueous binder system comprising a mixture of at least one silicate, at least one phosphate, at least one catalyst selected from the group consisting of carbonates aliphatic, cyclic alkylene carbonates, esters of aliphatic carboxylic acids, esters of cyclic carbaxyl acids, phosphate esters and mixtures thereof, and the particulate materials to be bound; said supply step comprises the in situ formation of the phosphate.

    SUMMARY OF THE INVENTION Inorganic baking binder compositions for agglomerating particulate materials and methods for curing such inorganic binders are presented. The inorganic binder compositions are composed of silicate and phosphate components. The non-cooking compositions further contain cation-curing catalyst, for example, a catalyst selected from the group consisting of aliphatic carbates, cyclic alkylene carbonates, aliphatic carboxylic acid esters, cyclic carboxylic acid esters, phosphate esters, and mixtures thereof. The compassion produces a binder having the advantageous strength properties of a silicate binder system with the water decomposing properties of a phosphate aglamer system. Thus, in comparison with a binder system that wears exclusively of silicate, the present invention has improved water removal capacity by improved shaking and an improved water decomposition capacity. Also, in comparison with a conventional binder system consisting exclusively of phosphate, the present invention has a superior thermal resistance, that is, the cores and casting molds do not soften at elevated temperatures. Methods for making and using the binder compositions as well as the resulting products are of particular interest in the field of smelting.