Foundry Binder Mixture and Foundry Moulding Material Mixture for Producing a Foundry Mould for Producing Foundry Moulds and Cores

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This invention relates to an improved foundry binder mixture and foundry molding material mixture for producing molds and cores used in metal casting. The binder system is based on inorganic, hydraulically hardening, ettringite-forming materials such as calcium aluminates, calcium sulfoaluminates, and sulfate carriers (e.g., various forms of calcium sulfate). By mixing the binder with an activator (typically water), rapid hardening and high early-stage strength are achieved, while avoiding environmentally and health-hazardous emissions commonly associated with organic binders. The invention also describes a process for producing the molding mixture and highlights its advantages in terms of speed and performance during mold-making.

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• Manufacture of large-scale foundry molds and cores for metal casting industries, especially for heavy and complex castings.
• Replacement of conventional organic binder systems in foundries to reduce hazardous emissions and improve workplace safety.
• Production of casting molds for automotive, industrial machinery, or infrastructure components where fast turnaround and mold strength are critical.
• Regeneration and recycling of foundry sands, thanks to the inorganic binder composition.
• Use in foundry operations requiring high reproducibility and dimensional accuracy of molds.

BenefitsContent extracted from patent full text and abstract with AI.

• Rapid hardening (within 6 hours) allows for faster mold production and shorter production cycles.
• High early strength, particularly under flexural load, increases mold reliability and reduces handling damage.
• No environmentally or health-damaging emissions during the casting process, promoting safer working conditions and simplified environmental compliance.
• Binder system can be adjusted for optimal properties (strength, gas permeability, processing time) with custom additives.
• Enables easy regeneration and re-use of the foundry sand due to the inorganic composition, reducing waste and costs compared to organic binder systems.
• Suitable for production of large and heavy cast parts, where conventional sand molds are inadequate.

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Patent Abstract

Die Erfindung betrifft eine Gießereibindermischung und eine Gießereiformstoffmischung zur Herstellung eines Gießereiformstoffs zur Herstellung von Gießereiformen und/oder-kernen und ein Verfahren zur Herstellung eines Gießereiformstoffs zur Herstellung von Gießereiformen und -kernen. Die Gießereibindermischung zur Herstellung eines Gießereiformstoffs zur Herstellung von Gießereiformen und/oder-kernen ist geeignet, durch Mischen mit einem Aktivator Ettringit zu bilden und enthält dabei 5 bis 80 Gew.-% mindestens eines Sulfatträgers, 20 bis 95 Gew.-% mindestens eines Calciumaluminats und/oder Calciumsulfoaluminats, 0 bis 30 Gew.-% mindestens einer calciumhaltigen Komponente und 0 bis 10 Gew.-% mindestens eines Additivs, wobei sich die Bestandteile der Gießereibindermischung zu 100 Gew.-% ergänzen.