Accelerated furanic aggregate binders from bio-derived components

Abstract

Broadly, the invention provides for newly available bio-derived formaldehyde-free furanic materials for aggregate binding. A specific example is aggregate binding for forms used in the metal casting process. The inventive binder formulations involve the use of 2,5-furan dimethanol and other “filler” components for high productivity and fast tensile development without formaldehyde, urea, urea-formaldehyde or formaldehyde containing compositions.

1 . A furanic binder composition comprising:
 a mixture of   a. a furfuryl alcohol;   b. about 1 to about 90 wt % 2,5-furan dimethanol, wherein the 2,5-furan dimethanol is derived from the reduction of 5-hydroxymethyl furfural;   c. about 0 to about 15 wt % resorcinol;   wherein the total of mixture a, b, and c comprises 100 wt %.   
     
     
         2 . The composition according to  claim 1 , wherein 2,5-furan dimethanol comprises about 5 to about 60 wt %. 
     
     
         3 . The composition according to  claim 1 , comprising a catalyst. 
     
     
         4 . The composition according to  claim 3 , wherein the catalyst comprises a weak acid having a pk a  between about 2 and about 4. 
     
     
         5 . The composition according to  claim 4 , wherein the catalyst comprises phosphoric acid. 
     
     
         6 . The composition according to  claim 1 , comprising an additive selected from the group consisting of iron oxide (red), iron oxide (black), Lewis acid, ground flax fiber, flour, and cellulosics. 
     
     
         7 . A method for making an aggregate casting comprising:
 a. using the composition of  claim 1 , to coat one aggregate material;   b. using a weak acid to coat another aggregate material;   c. mixing the coated aggregates from step a and step b above and blowing the mix together in a mold.   
     
     
         8 . The method according to  claim 7 , wherein the blowing is by compressed gas, air, or with a piston or ram. 
     
     
         9 . A furanic binder composition comprising:
 a mixture of   a. a furfuryl alcohol;   b. about 1 to about 90 wt % 2,5-furan dimethanol,   c. about 1 to about 30 wt % aromatic polyester polyol; and   d. about 0 to about 15 wt % resorcinol;   wherein the total of mixture a, b, c, and d comprises 100 wt %; and   wherein the substantially no formaldehyde is present.   
     
     
         10 . The composition according to  claim 9 , wherein the 2,5-furan dimethanol is derived from the reduction of 5-hydroxymethyl furfural. 
     
     
         11 . The composition according to  claim 9 , wherein 2,5-furan dimethanol comprises about 5 to about 60 wt %. 
     
     
         12 . The composition according to  claim 9 , comprising a catalyst. 
     
     
         13 . The composition according to  claim 12 , wherein the catalyst comprises a weak acid having a pk a  between about 2 and about 4. 
     
     
         14 . The composition according to  claim 13 , wherein the catalyst comprises phosphoric acid. 
     
     
         15 . The composition according to  claim 9 , comprising an additive selected from the group consisting of iron oxide (red), iron oxide (black), Lewis acid, ground flax fiber, flour, and cellulosics. 
     
     
         16 . A method for making an aggregate casting comprising:
 a. using the composition of  claim 9 , to coat one aggregate material;   b. using a weak acid to coat another aggregate material;   c. mixing the coated aggregates from step a and step b above and blowing the mix together in a mold.   
     
     
         17 . The method according to  claim 16 , wherein the blowing is by compressed gas, air, or with a piston or ram.