Furanic resin aggregate binders and method

Abstract

Broadly, the invention provides for newly available bio-derived formaldehyde free furanic materials for aggregate binding. The specific example case is aggregate binding for forms used in the metal casting process. The new materials make possible higher productivity and lower phenol, formaldehyde, urea, and/or furfuryl alcohol content in the metal casting form-making process. It is expected that the formulations will work well in other aggregate binding situations as well.

1 . A furanic acid-cured resin composition comprising:
 a. a substantially phenol, nitrogen, and formaldehyde-free formulation of furfuryl alcohol mixed with;   b. (1) about 1 to about 45 wt % 5-hydroxymethyl furfural; or
 (2) about 1 to about 60 wt % 2,5-furan dimethylol; or 
 (3) about 1 to about 40 wt % 2,5-furan dicarboxylic acid; or 
 (4) about 1 to about 60 wt % 2,5-diformyl furan; or 
 (5) about 1 to about 20 wt % polyester polyol; 
   
       or mixtures of two or more selected from b(1) through b(5). 
     
     
         2 . The composition according to  claim 1 , further comprising a catalyst in contact with the composition. 
     
     
         3 . The composition according to  claim 2 , wherein the catalyst is a weak acid. 
     
     
         4 . The composition according to  claim 3 , wherein the pK a  of the weak acid is between about 2 to about 6. 
     
     
         5 . The composition according to  claim 4 , wherein the pK a  of the weak acid is selected from the group consisting of phosphoric acid, nitrous acid, citric acid, formic acid, and the like, polyacrylic acid, and mixtures thereof. 
     
     
         6 . The composition according to  claim 1 , further comprising resorcinol accelerator. 
     
     
         7 . The composition according to  claim 1 , further comprising an aggregate coated catalyst in contact with the composition. 
     
     
         8 . The composition according to  claim 1 , wherein about 1 weight % and 90 weight % of furfuryl alcohol is replaced with blends of 5-hydroxymethyl furfural and 2,5-furan dimethylol at wt % ratios between the two components of about 5 to about 955-hydroxymethyl furfural to 2,5-furan dimethylol, to about 95 to about 55-hydroxymethyl furfural to 2,5-furan dimethylol. 
     
     
         9 . A furanic acid-cured resin composition comprising:
 a. a substantially phenol, nitrogen, and formaldehyde-free formulation of furfuryl alcohol mixed with;   b. (1) about 1 to about 20 wt % 5-hydroxymethyl furfural; or
 (2) about 1 to about 30 wt % 2,5-furan dimethylol; or 
 (3) about 1 to about 10 wt % 2,5-furan dicarboxylic acid, or 
 (4) about 1 to about 25 wt % 2,5-diformyl furan; or 
 mixtures of two selected from b(1) through b(4). 
   
     
     
         10 . The composition according to  claim 9 , further comprising a catalyst in contact with the composition. 
     
     
         11 . The composition according to  claim 10 , wherein the catalyst is a weak acid. 
     
     
         12 . The composition according to  claim 11 , wherein the pK a  of the weak acid is between about 2 to about 6. 
     
     
         13 . The composition according to  claim 12 , wherein the pK a  of the weak acid is selected from the group consisting of phosphoric acid, nitrous acid, citric acid, formic acid, and the like, polyacrylic acid, and mixtures thereof. 
     
     
         14 . The composition according to  claim 9 , further comprising resorcinol accelerator. 
     
     
         15 . The composition according to  claim 9 , further comprising an aggregate coated catalyst in contact with the composition. 
     
     
         16 . The composition according to  claim 9 , wherein about 1 weight % and 90 weight % of furfuryl alcohol is replaced with blends of 5-hydroxymethyl furfural and 2,5-furan dimethylol at wt % ratios between the two components of about 5 to about 955-hydroxymethyl furfural to 2,5-furan dimethylol, to about 95 to about 55-hydroxymethyl furfural to 2,5-furan dimethylol. 
     
     
         17 . A furanic acid-cured resin composition comprising:
 a. a substantially phenol, nitrogen, and formaldehyde-free formulation of furfuryl alcohol mixed with;   b. (1) about 1 to about 20 wt % 5-hydroxymethyl furfural; and
 (2) about 1 to about 30 wt % 2,5-furan dimethylol. 
   
     
     
         18 . The composition according to  claim 17 , further comprising a catalyst in contact with the composition. 
     
     
         19 . The composition according to  claim 18 , wherein the catalyst is a weak acid. 
     
     
         20 . The composition according to  claim 19 , wherein the pK a  of the weak acid is between about 2 to about 6.