Patent ID: 6772820
Filing Date: 2004-08-10
Classification: B22C

Abstract:
A process for preparing a foundry shape by the cold-box process which comprise:(a) forming a foundry mix comprising a major amount of aggregate and an effectively binding amount of a binding system comprising: (i) a phenolic resole resin component, and (ii) an isocyanate component, wherein the phenolic resin component comprises (a) an alkoxy-modified phenolic resole resin component such that the mole ratio of alcohol to phenol used to prepare said alkoxy-modified phenolic resole resin is less than 0.25:1, and (b) at least one oxyen-rich, polar organic solvent component, wherein the solvent portion of the phenolic resin component of the binder system amounts to no more than 40% by weight based upon the weight of the phenolic resin component and the amount of oxyen-rich polar organic solvent is at least 50 weight percent based on the total weight of the solvent in the phenolic resin component; and wherein either the phenolic resin component, isocyanate component, or both of said components contain a fatty acid ester having from 1 to 12 carbon atom in the alcohol chain of the fatty acid ester; (b) forming a foundry shape by introducing the foundry mix obtained from step (a) into a pattern; (c) contacting the foundry mix with a volatile tertiary amine catalyst;and (d) removing the foundry shape of step (c) from the pattern.