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 Resin-coated sand composition and method for producing same

Details
Inventors: Matsushima, Noriaki; Saeki, Yukio; Kirabayashi, Hajime;
Assignee: Sumitomo Durez Company, Ltd. (Tokyo, JP)
Primary Examiner: Jacobs; Lewis T.
Assistant Examiner:
Attorney, Agent or Firm: Tao; James F., Mudd; James F.

An improved resin binder for shell-molding operations having improved shake-out properties is disclosed. The resin binder utilizes a lubricant-containing phenolic resin of the novolac or resole type, or a mixture of novolac and resole types, incorporated therewith is an organic chloride. The organic chloride is characterized by having 20% by weight of the heating loss in the temperature range of 130.degree. to 550.degree. C. The organic chloride may be selected from chloride-containing polymers and cyclo-organic chlorides. Chlorinated polymeric material may be selected from polyvinyl chlorides, polyvinyldene chloride resins, chlorinated paraffins and chlorinated polyolefins.

DETAILED DESCRIPTION OF THE INVENTION In order to improve the shake-out property after casting metals having a low melting temperature such as aluminum, the chemical crosslinking structure of cured phenolic resin binders must thermally be degraded and cracked at a relatively lower temperature range of 300.
degree.
to 400.
degree.
C.
In ordinary phenolic resins, whether they be novolac type or resole type resins, said chemical crosslinking structure therein consists of such as methylene, methine and dimethylene-ether groups.
Among them, the dimethylene-ether group changes by heat to a methylene group.
On the other hand, both the methylene and methine groups are stable to thermal decomposition, and they require much more energy for decomposition.
Both the methylene and methine groups gradually begin to decompose at about 250.
degree.
C.
, however, a higher, temperature range of 600.
degree.
to 1000.
degree.
C.
is necessary for rapidly decomposing the major portion thereof.
The thermal decomposition of phenolic resins is thought to be a thermal oxidative process whether exposed to either an oxidative or inert atmosphere.
In an inert atmosphere, it is thought that much of the oxygen contained therein contributes to initiation of a oxidative reaction.
It is further thought that both methylene and methine groups change to hydroperoxides due to said thermal oxidation, and finally yield carboxylic acids through cracking of dihydrobenzophenone.
Accordingly, in order to lower the activation energy of decomposition reaction of methylene and methine groups, namely, to lower the decomposition temperature of phenolic resins to the range of 300.
degree.
to 400.
degree.
C.
, incorporating a compound having a catalytic effect thereof is an effective method for causing a thermal disintegration of the sand mold.
The additives suitable for the purpose will generally be several kinds of oxidants.
The inventors have discovered that the presence of one or more organic chlorides, having the 20 percent by weight of the heating loss in the temperature range of 130



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