Patent ID: 6378599
Filing Date: 2002-04-30
Classification: C01P,C03C,C09C,C09D

Abstract:
A method of manufacturing a foundry mold or core material comprising foundry mold of core sand and, as a binder, a nanocomposite sol or factory binder prepared therefrom, the method comprising the steps of:(1) surface modifying colloidal inorganic particles with one or more silanes of the general formula Rxâ€”Siâ€”A4âˆ’x where each A is independently selected from hydroxyl and groups that are hydrolytically removable but are not methoxy, each R is independently selected from groups that are not hydrolytically removable, and x is 0, 1, 2, or 3, where x &gE;1 in at least 50 mol % of the silanes; â€ƒunder sol-gel process conditions with a quantity of water that is sub-stoichiometric based on the quantity of hydrolytically removable groups present on the silanes, thereby preparing the nanocomposite sol; (2) optionally-hydrolyzing and condensing the nanocomposite sol, thereby forming the foundry binder; (3) optionally activating the foundry binder with an additional quantity of water; and (4) combining the nanocomposite sol or foundry binder with foundry mold or core sand to form the foundry mold or core material.