Patents by Inventor Ken K. Chang
Ken K. Chang has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 7125914Abstract: This invention relates to a heat-cured furan foundry binder system comprising a furan binder and a furan monomer or oligomer containing at least two terminal hydroxymethyl groups. The binders are particularly useful as warm-box binders, because they cure faster and foundry shapes (typically cores and molds) made with the binders exhibit higher tensile strengths than those made with conventional heat-cured furan binders.Type: GrantFiled: September 18, 2003Date of Patent: October 24, 2006Assignee: Ashland Licensing and Intellectual Property LLCInventor: Ken K. Chang
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Patent number: 6593397Abstract: This invention relates to furan no-bake foundry binders comprising (a) furfuryl alcohol and/or a reactive furan resin, (b) an activator selected from the group consisting of resorcinol, resorcinol pitch, and bisphenol A tar (c) a bisphenol compound (d) a polyol selected from the group consisting of polyester polyols, polyether polyols, and mixtures thereof, and preferably (e) a silane. The binders are cured in the presence of the furan curing catalyst. The invention also relates to foundry mixes prepared with the binder, foundry shapes prepared with the foundry mix, and metal castings prepared with the foundry shapes.Type: GrantFiled: September 10, 2002Date of Patent: July 15, 2003Assignee: Ashland Inc.Inventor: Ken K. Chang
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Patent number: 6559203Abstract: This invention relates to an organic foundry binder containing an alkyl resorcinol, or preferably a readily available mixture of alkyl resorcinols, and derivatives thereof. Preferably, the organic foundry binder is a furan binder. Foundry mixes are prepared by mixing the binder with a foundry aggregate. Foundry shapes (molds and cores) are prepared by shaping the mix and allowing it to cure to form a workable foundry shape. The invention also relates to the preparation of metal castings using the foundry shapes and the metal castings prepared with the foundry shapes.Type: GrantFiled: February 13, 2002Date of Patent: May 6, 2003Assignee: Ashland Inc.Inventors: David A. Hutchings, Heimo J. Langer, Ken K. Chang, Thomas E. Dando
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Publication number: 20030055125Abstract: This invention relates to an organic foundry binder containing an alkyl resorcinol, or preferably a readily available mixture of alkyl resorcinols, and derivatives thereof. Preferably, the organic foundry binder is a furan binder. Foundry mixes are prepared by mixing the binder with a foundry aggregate. Foundry shapes (molds and cores) are prepared by shaping the mix and allowing it to cure to form a workable foundry shape. The invention also relates to the preparation of metal castings using the foundry shapes and the metal castings prepared with the foundry shapes.Type: ApplicationFiled: February 13, 2002Publication date: March 20, 2003Inventors: David A. Hutchings, Heimo J. Langer, Ken K. Chang, Thomas E. Dando
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Publication number: 20030036583Abstract: This invention relates to furan no-bake foundry binders comprising (a) furfuryl alcohol and/or a reactive furan resin, (b) an activator selected from the group consisting of resorcinol, resorcinol pitch, and bisphenol A tar (c) a bisphenol compound (d) a polyol selected from the group consisting of polyester polyols, polyether polyols, and mixtures thereof, and preferably (e) a silane. The binders are cured in the presence of the furan curing catalyst. The invention also relates to foundry mixes prepared with the binder, foundry shapes prepared with the foundry mix, and metal castings prepared with the foundry shapes.Type: ApplicationFiled: September 10, 2002Publication date: February 20, 2003Applicant: Ashland Inc.Inventor: Ken K. Chang
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Patent number: 6479567Abstract: This invention relates to furan no-bake foundry binders comprising (a) furfuryl alcohol and/or a reactive furan resin, (b) an activator selected from the group consisting of resorcinol, resorcinol pitch, and bisphenol A tar (c) a bisphenol compound (d) a polyol selected from the group consisting of polyester polyols, polyether polyols, and mixtures thereof, and preferably (e) a silane. The binders are cured in the presence of the furan curing catalyst. The invention also relates to foundry mixes prepared with the binder, foundry shapes prepared with the foundry mix, and metal castings prepared with the foundry shapes.Type: GrantFiled: March 3, 2000Date of Patent: November 12, 2002Assignee: Ashland Inc.Inventor: Ken K. Chang
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Patent number: 6391942Abstract: This invention relates to furan no-bake foundry binders comprising (a) a reactive furan resin, (b) furfuryl alcohol, and (c) a catalyst component comprising a catalytically effective amount of a Lewis acid furan catalyst. The invention also relates to foundry mixes prepared with the binder, foundry shapes prepared with the foundry mix, and metal castings prepared with the foundry shapes.Type: GrantFiled: April 27, 2000Date of Patent: May 21, 2002Assignee: Ashland Inc.Inventors: Ken K. Chang, David A. Hutchings
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Patent number: 6291550Abstract: This invention relates to a solventless polyurethane no-bake foundry binder system comprising, as individual components (a) a polyol component comprising a polyether polyol, glycol, and an aromatic polyester polyol, (b) an organic polyisocyanate component, and (c) a liquid tertiary amine catalyst component. Foundry mixes are prepared by mixing the binder system with a foundry aggregate by a no-bake process. The resulting foundry shapes are used to cast metal parts from ferrous and non-ferrous metals.Type: GrantFiled: March 3, 2000Date of Patent: September 18, 2001Assignee: Ashland Inc.Inventors: Chia-hung Chen, Ken K. Chang
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Patent number: 6063833Abstract: This invention relates to a solventless polyurethane no-bake foundry binder system comprising, as individual components (a) a polyol component comprising a polyether polyol, glycol, and an aromatic polyester polyol, (b) an organic polyisocyanate component, and (c) a liquid tertiary amine catalyst component. Foundry mixes are prepared by mixing the binder system with a foundry aggregate by a no-bake process. The resulting foundry shapes are used to cast metal parts from ferrous and non-ferrous metals.Type: GrantFiled: January 8, 1999Date of Patent: May 16, 2000Assignee: Ashland Inc.Inventors: Chia-hung Chen, Ken K. Chang
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Patent number: 6017978Abstract: This invention relates to a polyurethane no-bake foundry binder comprising (1) phenolic resin component which comprises (a) a phenolic resin, (b) hydrofluoric acid, and (c) a silane, and (2) an organic polyisocyanate component, and (3) a liquid tertiary amine catalyst component. The binders are used to prepare foundry mixes by mixing the binder with a foundry aggregate. Foundry shapes are prepared with the mixes by the no-bake process and are used to cast metal parts.Type: GrantFiled: February 28, 1998Date of Patent: January 25, 2000Assignee: Ashland Inc.Inventors: Chia-hung Chen, Ken K. Chang, Albert Leonard Haugse, Thomas E. Dando
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Patent number: 5856375Abstract: Broadly, the present invention relates to furan no-bake foundry binders where bisphenol A tar (BPAT) is used to replace a portion of the furfuryl alcohol and any conventional filler optionally included in for binder formulation. Reduction in the amount of furfuryl alcohol in the foundry binder formulation may lead to a reduction in the cost and an improvement in early strength of these formulations. Accordingly, in a furan no-bake foundry binder of a resin derived from a major proportion of furfuryl alcohol and optionally fillers, the improvement which comprises at least a fraction of said furfuryl alcohol being bisphenol A tar. Bisphenol A tar also can replace at least a fraction of any filler included in the binder formulation.Type: GrantFiled: January 4, 1996Date of Patent: January 5, 1999Assignee: Ashland, Inc.Inventors: Ken K. Chang, Michael C. Clingerman, Michelle L. Lott, James T. Schneider
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Patent number: 5612392Abstract: This invention relates to a heat cured foundry binder system comprising as separate components (A) a furan resin, and (B) an effective amount of a curing catalyst composition comprising water, a copper aryl sulfonate, a aryl sulfonic acid, preferably polyvinyl alcohol, and a copper halide.Type: GrantFiled: May 16, 1995Date of Patent: March 18, 1997Assignee: Ashland Inc.Inventors: Ken K. Chang, Thomas E. Dando, A. Leonard Haugse
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Patent number: 5516859Abstract: This invention relates to polyurethane-forming foundry no-bake binder systems comprising a phenolic resin component and polyisocyanate component. The phenolic resin component comprises a blend of (a) polyphenol resin and (b) a phenolic resole resin. The binder systems have reduced phenol and free formaldehyde due to the presence of the polyphenol resin in the phenolic resin component. Foundry shapes are made by the no-bake process and are used in making ferrous and non ferrous metal castings.Type: GrantFiled: November 23, 1993Date of Patent: May 14, 1996Assignee: Ashland Inc.Inventors: William R. Dunnavant, Ken K. Chang, Robert B. Fechter
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Patent number: 5424376Abstract: The invention relates to an ester cured no-bake foundry binder system preferably comprising as separate components (a) an aqueous basic solution of a phenolic resole resin; and (b) a hardener comprising (i) a polyphenol resin, and (ii) a liquid ester. Alternatively, the polyphenol resin can be used as a separate component. The foundry binder systems produce foundry shapes with improved tensile strengths when compared to foundry shapes which are prepared from foundry binder systems which do not contain a polyphenol resin.Type: GrantFiled: October 4, 1993Date of Patent: June 13, 1995Assignee: Ashland Inc.Inventors: Ken K. Chang, William R. Dunnavant, Robert B. Fechter, Gary R. Hysell
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Patent number: 5254642Abstract: The present invention is based on the unexpected discovery that the low profile additives (LPA) disclosed in U.S. Pat. No. 5,116,917 provide effective shrinkage control when used with various blends of vinyl ester and polyester resin systems. This LPA is unique in that its low profile efficiency is not affected by the different reactivities displayed by blends of vinyl ester resin and polyester resin at different blend ratios. This LPA is equally effective in formulations of all vinyl ester resin, all polyester resin, or any combination of such two resins. The present invention, then, is directed to a thermosettable resinous composition of between about 0 and 95 wt-% of a thermosettable vinyl ester resin; between about 5 and 100 wt-% of a thermosettable polyester resin; and between about 5 and 40 wt-% of a low profile additive comprising a non-gelling, saturated polyester formed from dibasic acid and an EO/PO block copolymer having an EO/PO molar ratio ranging from about 0.1 to 0.Type: GrantFiled: September 12, 1992Date of Patent: October 19, 1993Assignee: Ashland Oil, Inc.Inventors: Ken K. Chang, Timothy A. Tufts
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Patent number: 5116917Abstract: The present invention is directed to a thermosettable vinul ester resinous composition and low profile additive. The improvement comprises the low profile additive comprising a non-gelling, saturated polyester formed from dibasic acid and an ethylene oxide/propylene oxide polyether polyol having an EO/PO molar ratio ranging from about 0.1 to 0.9. The polyester has an acid value of greater than about 10 and preferably has a molecular weight of greater than about 6,000. The EO/PO polyether polyol can be built on a combination of diol, triol or other compound with active hydrogen groups, so long as the LPA product does not gel.Type: GrantFiled: December 11, 1990Date of Patent: May 26, 1992Assignee: Ashland Oil, Inc.Inventors: Ken K. Chang, Timothy A. Tufts