I 1111111111111111 11111 1111111111 11111 111111111111111 111111111111111 IIII IIII  US009993 863B2  c12)  United States Patent  Fourberg et al.  (54)  LOW-EMISSION COLD-SETTING BINDER  FOR THE FOUNDRY INDUSTRY  (IO)  Patent No.:  US 9,993,863 B2  Jun.12,2018  (45)  Date of Patent:  (75)  Inventors:  Christian Fourberg,  Miinchengladbach  (DE);  Gerard Ladegourdie,  Dusseldorf  (DE);  Norbert Benz,  Miinchengladbach  (DE);  Eckard Piech,  Bergfeld (DE)  (73)  Assignee:  HUTTENES-ALBERTUS  CHEMISCHE WERKE GMBH,  Dusseldorf (DE)  ( *)  Notice:  Subject to any disclaimer, the term ofthis  patent is extended or adjusted under 35  U.S.C. 154(b) by 387 days.  (21)  Appl. No.:  13/984,481  (22)  PCT Filed:  Dec. 16, 2011  (86)  PCT No.:  PCT/EP2011/073023  § 371 (c)(l),  (2), ( 4) Date:  Oct. 11, 2013  (87)  PCT Pub. No.:  WO2012/080454  PCT Pub. Date:  Jun. 21, 2012  (51)  Int. Cl.  (52)  U.S. Cl.  CPC ....................................  B22C 11224  (2013.01)  ( 58)  Field of Classification Search  CPC ...................................................... B22C 1/224  US 2014/0048740 Al  Feb. 20, 2014  Dec. 16, 2010  (DE) ........................ 10 2010 063 256  B22C 1122  (2006.01)  See application file for complete search history.  (74)  Attorney, Agent, or Firm  - Duane Morris LLP;  Gregory M. Lefkowitz; Jason M. Nolan  Primary Examiner  - Amina S Khan  * cited by examiner  Delivery note n. Bl 1287 of the Giocaset resin supply, issued on  Jun. 9, 2010 by Cavenaghi to carry the Giocaset resin to F onderian  Boccacci s.p.a., via XXV Apr. 9, 19020 Piana Batolla (SP)-Italy.  Invoice N. 1302 of Jun. 11, 2010 for the Giocaset resin supply, issue  by Cavenaghi to Fonderia Boccacci s.p.a., wherein the delivery  note. Bl 1287 is referrred to in the filed "Description of goods."  Delivery note n. Bl 1644 of the Giocaset resin supply, issued on Jul.  22, 2010 by Cavenaghi to carry the Giocaset resin to Fonderia  Boccacci s.p.a.  Invoice N. 1695 of Jul. 23, 2010 for the Giocaset resin supply,  issued by Cavenaghi to Fonderia Boccacci s.p.a., wherein the  delivery note n. Bl 1644 is referred to in the filed "Description of  goods."  Certificate of Analysis n. 513-C relating to the resin KH-Y.  Certificate of Analysis n. 511-C relating to the above-mentioned  Giocaset NB 2500 resin.  Third party observation correspondence from Dragotti & Associati  to the European Patent Office, dated Dec. 11, 2014.  European Standard, Phenolic, amino and condensation resins› Determination of free-formaldehyde content (ISO 11402:2004), EN  ISO 11402, Feb. 2005, 22 pages.  Authorization Letter, "Authorization for reproducing the UNI EN  ISO 11402: 2005 standard", Italian National Unification Associa› tion, Dated Aug. 4, 2017, 2 pages.  Gardziella et al., Phenolic Resins, Chemistry, Applications, Stan› dardization, Safety and Ecology, 2nd completely revised edition, 7  Chemical, Physical and Application Technology Parameters of  Phenolic Resins, 2000, 3 pages.  ECHA, European Chemicals Agency, Substance Information,  Hydroxylammonium Chloride, retrieved from the internet on Feb.  8, 2017, 2 pages.  Cavenaghi, "GIOCASET NB 2500 Resin, formaldehyde content  analysis", 22 and Aug. 23, 2017, 2 pages.  Decreto Legislativo, English Translation Exceprt From p. 55.  www.  gazzettaufficiale.it/atto/stampa/serie_generale/ originario, Aug. 23,  2017, p. 55 of 139, 2 pages.  Cavenaghi, "Naming and coding of raw material, packagings and  finished products", Operating Instruction O.I. Aug. 1, 2002. Review  4 of the Dec. 6, 2009, 2 pages.  Cavenaghi, Form, "Naming and coding of new products/raw mate› rials", CodiProd.doc-review 3 of the Jan. 30, 2009, 2 pages.  Cavenaghi, Form, "Product Links (for product coding)", legami.  doc-review of the Apr. 16, 2010, 2 pages.  The present invention relates primarily to a mixture that is  suitable for use in the no-bake process for producing cores  and molds for the foundry industry, and a reaction mixture  comprising said mixture and an acid hardener (i.e. an acid  catalyst). The present invention further relates to a method  of producing a mixture according to the invention and a  method of producing a mold or a core. The invention also  relates to a mold or a core for producing metal objects and  a kit comprising a mixture according to the invention and  certain acid hardeners. The invention further relates to the  use of a mixture according to the invention as cold-setting  binder and the use of said mixtures or reaction mixtures in  a no-bake process for producing metal objects.  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