US 12,083,584 B2
Halloysite clay as smoke-reducing additive for polyurethane-forming binder system
Paula Vivas, Dublin, OH (US); Matthew Shoffner, Dublin, OH (US); and Lee Horvath, Powell, OH (US)
Assigned to ASK Chemicals LLC, Wilmington, DE (US)
Appl. No. 17/786,208
Filed by ASK Chemicals LLC, Wilmington, DE (US)
PCT Filed Jan. 11, 2022, PCT No. PCT/US2022/011987
§ 371(c)(1), (2) Date Jun. 16, 2022,
PCT Pub. No. WO2022/155137, PCT Pub. Date Jul. 21, 2022.
Claims priority of provisional application 63/136,431, filed on Jan. 12, 2021.
Prior Publication US 2023/0249244 A1, Aug. 10, 2023
Int. Cl. B22C 1/02 (2006.01); B22C 1/22 (2006.01)
CPC B22C 1/02 (2013.01) [B22C 1/2273 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A foundry mix composition, comprising:
a polyurethane binder precursor, provided in two parts, the first part comprising a polyol component and the second part comprising a polyisocyanate component;
a liquid curing catalyst;
a foundry aggregate; and
a halloysite clay, present in the range of from about 1 to about 4 wt %, based on the weight of the foundry aggregate.
 
15. A method for preparing a foundry mix, comprising the steps of:
adding a halloysite clay to a foundry aggregate and mixing, wherein the halloysite clay is present in an amount in the range of about 1 to about 4 wt %, based on the weight of the foundry aggregate;
adding, to the mixed halloysite clay and foundry aggregate, a first part of a polyurethane binder precursor and a liquid curing catalyst and mixing, the first part of the polyurethane binder precursor comprising a polyol component; and
adding a second part of the polyurethane binder precursor, the second part of the polyurethane binder precursor comprising a polyisocyanate component.
 
19. A foundry mold or core, comprising the foundry mix composition according to claim 1.
 
20. A no bake process for preparing a foundry shape, comprising the steps of:
providing an amount of the foundry mix composition of claim 1;
mixing intimately the halloysite clay with the foundry aggregate;
preparing a foundry molding compound by separately mixing the polyurethane binder precursor and the liquid curing catalyst with the mixed halloysite clay and foundry aggregate;
inserting the foundry molding compound into a pattern, allowing the mixture to cure into a foundry shape, and
removing the foundry shape from the pattern.