Compositions and methods for refractory coatings with ester carriers

Abstract

This technology relates to refractory coatings used in metal casting by the foundry industry. Refractory coatings are often used to coat foundry cores and molds for the purpose of improving the quality of castings formed in connection with the cores or molds, particularly at the surface of the casting. Whereas traditional coatings comprise water based solvents that require excessive drying times or HAPs that emit hazardous VOCs, preferred embodiments of the present invention comprise refractory coatings having VOC-exempt ester based solvents, such as a dimethyl carbonate (DMC). Other preferred embodiments of the present invention comprise methods for reduction of VOC content in a foundry article.

1 . A refractory coating composition for foundry use comprising:
 a liquid carrier comprising an ester carrier, the ester carrier being provided at approximately 25% to 100% by weight of the liquid carrier and 25% to 32.5% by weight of the composition;   a binder;   water provided at up to approximately 2% by weight of the composition;   one or more additives provided at up to approximately 2% by weight of the composition; and   a particulate refractory material provided at approximately 13 to 78.5% by weight of the composition.   
     
     
         2 . The refractory coating composition of  claim 1 , wherein the binder is provided at approximately 0.4% to 3% by weight of the composition. 
     
     
         3 . The refractory coating composition of  claim 1 , wherein the ester carrier is t-butyl acetate. 
     
     
         4 . The refractory coating composition of  claim 1 , wherein the ester carrier is a carbonate ester. 
     
     
         5 . The refractory coating composition of  claim 4 , wherein the carbonate ester is dimethyl carbonate. 
     
     
         6 . The refractory coating composition of  claim 5 , further comprising a suspending agent provided at 2% or less by weight of the composition. 
     
     
         7 . The refractory coating composition of  claim 6 , wherein the suspending agent is an organoclay, the binder is a copolymer, and the particulate refractory material comprises zircon, aluminum silicate, silica, alumina, or a combination of the foregoing particulate refractory materials. 
     
     
         8 . The refractory coating composition of  claim 4 , wherein the binder is a vinyl acetate and vinyl laurate copolymer provided at approximately 50% by weight of the binder. 
     
     
         9 . The refractory coating composition of  claim 4 , wherein the additive is a wetting agent, defoamer, dispersant, or a rheology modifier. 
     
     
         10 . The refractory coating composition of  claim 4 , wherein the particulate refractory material is a zirconium silicate flour having an average particle size of approximately d<30 microns, and wherein no greater than approximately 10% by weight or volume of the particulate refractory material has a particle size of approximately d<2 microns. 
     
     
         11 . The refractory coating composition of  claim 4 , the liquid carrier further comprising a volatile organic carrier. 
     
     
         12 . The refractory coating composition of  claim 11 , wherein the volatile organic carrier is isopropyl alcohol. 
     
     
         13 . The refractory coating composition of  claim 4 , wherein the binder is a natural rosin or a hydrocarbon resin.