Phenolic resin compositions and their use in foundry binders

Abstract

This invention relates to phenolic resin compositions containing propylene glycol mono methyl ether acetate as a solvent. It also relates to the use of these compositions in foundry binders.

I claim: 
     
       1. A phenolic resin composition comprising: a. a phenolic resin; and b. a solvent composition comprising: i. propylene glycol mono methyl ether acetate; and   ii. an aromatic hydrocarbon solvent wherein the weight ratio of (a) to (b) is from 45:55 to 55:45, and the weight ratio of (i) to (ii) is from 1:2 to 2:1.   
     
     
       2. The phenolic resin composition of claim 1 wherein the phenolic resin is a resole resin prepared by reacting an aldehyde with a phenolic compound such that the molar ratio of aldehyde to phenolic compound is from 1.1:1.0 to 2.0:1.0. 
     
     
       3. The phenolic resin composition of claim 2 wherein the phenolic resin is prepared by reacting the aldehyde and phenolic compound in the presence of a divalent metal catalyst. 
     
     
       4. The phenolic resin composition of claim 3 wherein the phenolic compound is selected from the group consisting of phenol, o-cresol, p-cresol, and mixtures thereof. 
     
     
       5. The phenolic resin composition of claim 4 wherein the aldehyde is formaldehyde. 
     
     
       6. The phenolic resin composition of claim 5 wherein the weight ratio of the phenolic resin .Iadd.to solvent composition .Iaddend.is from 47:53 to 51:49 .[.weight percent based upon the total weight of the phenolic resin composition.].. 
     
     
       7. A foundary binder comprising in admixture: a. the phenolic resin composition of claim 1:   b. a polyisocyanate composition.   
     
     
       8. The foundry binder of claim 7 wherein the phenolic resin composition contains a liquid urethane promoting curing catalyst. 
     
     
       9. The foundary binder of claim 8 wherein the phenolic resin is a resole resin prepared by reacting an aldehyde with a phenolic compound such that the molar ratio of aldehyde to phenolic compound is from 1.1:1.0 to 2.0:1.0. 
     
     
       10. The foundary binder of claim 9 wherein the phenolic resin is prepared by reacting the aldehyde and phenolic compound in the presence of a divalent metal catalyst. 
     
     
       11. A foundry mix comprising: a. a major amount of foundry aggregate   b. an effective bonding amount of the foundary binder of claim 7.   
     
     
       12. The foundry mix of claim 11 wherein said foundry binder is the foundry binder of claim 8. 
     
     
       13. A foundry binder comprising in admixture: a. the phenolic resin composition of claim 6; and   b. a polyisocyanate composition.   
     
     
       14. The foundry binder composition of claim 13 wherein the phenolic resin composition contains a liquid urethane promoting curing catalyst. .Iadd. 
     
     
       15.  A phenolic resin composition comprising: a. a phenolic resin; and   b. a solvent composition comprising: i. propylene glycol mono methyl ether acetate; and   ii. an aromatic hydrocarbon solvent wherein the weight ratio of (a) to (b) is from 45:55 to 55:45, and the weight ratio of (i) to (ii) is from 4:1 to 1:4. .Iaddend. .Iadd.16. The phenolic resin composition of claim 15 wherein the phenolic resin is a resole resin prepared by reacting an aldehyde with a phenolic compound such that the molar ratio of aldehyde to phenolic compound is from 1.1:1.0 to 2.0:1.0. .Iaddend. .Iadd.17. The phenolic resin composition of claim 16 wherein the phenolic resin is prepared by reacting the aldehyde and phenolic compound in the presence of a divalent metal catalyst. .Iadd.18. The phenolic resin composition of claim 17 wherein the phenolic compound is selected from the group consisting of phenol, o-cresol, p-cresol, and mixtures thereof. .Iaddend. .Iadd.19. The phenolic resin composition of claim 18 wherein the aldehyde     
     
     
        is formaldehyde. .Iaddend. .Iadd.20.  The phenolic resin composition of claim 19 wherein the weight ratio of the phenolic resin to solvent 
     
     
        composition is from 47:53 to 51:49. .Iaddend. .Iadd.21.  A foundry binder comprising in admixture: a. the phenolic resin composition of claim 15;   b. a polyisocyanate composition. .Iaddend. .Iadd.22. The foundry binder of claim 21 wherein the phenolic resin composition contains a liquid urethane promoting curing catalyst. .Iaddend. .Iadd.23. The foundry binder of claim 22 wherein the phenolic resin is a resole resin prepared by reacting an aldehyde with a phenolic compound such that the molar ratio of aldehyde to phenolic compound is from 1.1:1.0 to 2.0:1.0. .Iaddend. .Iadd.24. The foundry binder of claim 23 wherein the phenolic resin is prepared by reacting the aldehyde and phenolic compound in the presence of a divalent metal catalyst. .Iaddend. .Iadd.25. A foundry mix comprising:   a. a major amount of foundry aggregate   b. an effective bonding amount of the foundry binder of claim 24. .Iaddend.