Patents by Inventor Antony George Schepak
Antony George Schepak 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: 10711680Abstract: An engine has a cylinder block with a deck face and at least one cylinder liner with a cylinder axis. The block has a first fluid jacket about the liner, a second fluid jacket about the liner, and a third fluid jacket about the liner. The first, second, and third fluid jackets are fluidly independent from one another and spaced apart from one another along the cylinder axis. A method for forming the engine includes using an insert to provide each of the fluid jackets. The insert has a lost core material surrounded by a metal shell.Type: GrantFiled: October 17, 2017Date of Patent: July 14, 2020Assignee: Ford Global Technologies, LLCInventors: Clifford E. Maki, Antony George Schepak
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Patent number: 10569368Abstract: A wire feed control system includes an anti-twist mechanism and a controller programmed to operate the anti-twist mechanism, responsive to a measured degree of twist of a wire on a trajectory between a feed for the wire and a plasma transfer wire arc (PTWA) torch, to maintain the degree of twist within a predetermined range defined by natural rotation introduced to the wire by the PTWA torch.Type: GrantFiled: July 13, 2017Date of Patent: February 25, 2020Assignee: FORD GLOBAL TECHNOLOGIES, LLCInventors: Clifford E. Maki, Antony George Schepak, James Maurice Boileau
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Patent number: 10337510Abstract: Oil pumps having wear-resistant coatings applied thereto and methods of applying the coatings are disclosed. The oil pump may include an aluminum housing that defines a cavity. A steel rotor may be disposed within the cavity and configured to rotate therein such that a portion of the steel rotor contacts the aluminum housing. A metal coating (e.g., steel) may cover at least a portion of the aluminum housing in a region that is configured to be contacted by the steel rotor. An integrated oil pump and engine cover is disclosed including an aluminum body having a peripheral wall defining a cavity. The peripheral wall may form a portion of the oil pump housing and the cavity may receive a steel rotor. A wear-resistant coating (e.g., steel) may cover at least a portion of the peripheral wall in a region that is configured to be contacted by the steel rotor.Type: GrantFiled: February 3, 2017Date of Patent: July 2, 2019Assignee: Ford Global Technologies, LLCInventors: Clifford E. Maki, Antony George Schepak, James Maurice Boileau
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Publication number: 20190015936Abstract: A wire feed control system includes an anti-twist mechanism and a controller programmed to operate the anti-twist mechanism, responsive to a measured degree of twist of a wire on a trajectory between a feed for the wire and a plasma transfer wire arch (PTWA) torch, to maintain the degree of twist within a predetermined range defined by natural rotation introduced to the wire by the PTWA torch.Type: ApplicationFiled: July 13, 2017Publication date: January 17, 2019Applicant: FORD GLOBAL TECHNOLOGIES, LLCInventors: Clifford E. Maki, Antony George Schepak, James Maurice Boileau
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Patent number: 10174707Abstract: A tool and a method of forming an engine using the tool are provided. The tool includes an insert and at least one die. The insert is formed by forming an interbore passage between first and second siamesed cylinder liners, casting a lost core, and then casting a metal shell. The insert is positioned into a die of the tool and the engine block is cast. The lost core material may then be removed to provide the cooling jacket. The engine includes a cylinder block with a cooling jacket circumferentially surrounding first and second siamesed cylinder liners intersecting a closed deck face. The cooling jacket has first and second widths in first and second axial sections, respectively. An interbore region of the first and second cylinder liners defines first and second interbore cooling passages spaced apart from the deck face and parallel to one another.Type: GrantFiled: March 9, 2017Date of Patent: January 8, 2019Assignee: Ford Global Technologies, LLCInventors: Clifford E. Maki, Antony George Schepak
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Patent number: 10132267Abstract: Engine blocks and methods of forming engine blocks are disclosed. The engine block may include a cast aluminum body and a plurality of cast-in liners. Each cast-in liner may include (a) an outer layer of 2xxx-series aluminum molecularly bonded to the cast aluminum body and (b) an inner layer directly contacting the outer layer and forming at least a portion of an engine bore. The inner layer may be a wear-resistant coating, such as a steel coating. The method may include extruding an elongated 2xxx-series aluminum extrusion having an inner cavity bounded by an inner surface and applying a wear-resistant coating to the inner surface. The extrusion may be sectioned into a plurality of cylinder liners and the cylinder liners may be into an aluminum engine block such that each cast-in liner forms at least a portion of an inner surface of an engine bore in the engine block.Type: GrantFiled: December 17, 2015Date of Patent: November 20, 2018Assignee: Ford Global Technologies, LLCInventors: Antony George Schepak, Clifford E. Maki, Mathew Leonard Hintzen
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Patent number: 10113502Abstract: A cylinder head includes an inner structural member having a plate forming a deck face of the cylinder head and forming at least one dished cylinder roof, and a plurality of cylinder head bolt columns extending from the plate. An outer member is supported by the inner structural member and forms a cooling jacket, intake ports, and exhaust ports. Passages of the cooling jacket are lined with metal walls in contact with the composite structure of the outer member. A method of forming a cylinder head includes positioning a structural insert and a lost core insert in a tool, and injecting material into the tool to form a body surrounding the structural insert and the lost core insert thereby forming a head preform. The lost core insert is shaped to form a cooling jacket and has a lost core material generally encapsulated in a metal shell.Type: GrantFiled: September 8, 2015Date of Patent: October 30, 2018Assignee: Ford Global Technologies, LLCInventors: Clifford E. Maki, Antony George Schepak, Mathew Leonard Hintzen, Mark W. Thibault, Christopher Donald Wicks
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Publication number: 20180258878Abstract: A tool and a method of forming an engine using the tool are provided. The tool includes an insert and at least one die. The insert is formed by forming an interbore passage between first and second siamesed cylinder liners, casting a lost core, and then casting a metal shell. The insert is positioned into a die of the tool and the engine block is cast. The lost core material may then be removed to provide the cooling jacket. The engine includes a cylinder block with a cooling jacket circumferentially surrounding first and second siamesed cylinder liners intersecting a closed deck face. The cooling jacket has first and second widths in first and second axial sections, respectively. An interbore region of the first and second cylinder liners defines first and second interbore cooling passages spaced apart from the deck face and parallel to one another.Type: ApplicationFiled: March 9, 2017Publication date: September 13, 2018Inventors: Clifford E. MAKI, Antony George SCHEPAK
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Patent number: 10066577Abstract: Extruded cylinder liners and methods of forming the same are disclosed. The extruded engine cylinder liner may include a cylindrical body having a longitudinal axis and defining an inner surface and an outer surface. A plurality of spaced apart features may protrude from the outer surface and may extend in a direction oblique to the longitudinal axis. The method may include extruding a metal material through a die to form a cylindrical body defining an inner surface and an outer surface and a plurality of spaced apart features protruding from the outer surface. The die may be rotated about a longitudinal axis during at least a portion of the extruding step such that the features extend in a direction oblique to the longitudinal axis. The oblique features may allow parent casting material to enter channels therebetween and prevent the liner from moving in the vertical and horizontal directions.Type: GrantFiled: February 29, 2016Date of Patent: September 4, 2018Assignee: Ford Global Technologies, LLCInventors: Clifford E. Maki, Antony George Schepak, Mathew Leonard Hintzen, James Maurice Boileau, Mark W. Thibault
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Publication number: 20180223835Abstract: Oil pumps having wear-resistant coatings applied thereto and methods of applying the coatings are disclosed. The oil pump may include an aluminum housing that defines a cavity. A steel rotor may be disposed within the cavity and configured to rotate therein such that a portion of the steel rotor contacts the aluminum housing. A metal coating (e.g., steel) may cover at least a portion of the aluminum housing in a region that is configured to be contacted by the steel rotor. An integrated oil pump and engine cover is disclosed including an aluminum body having a peripheral wall defining a cavity. The peripheral wall may form a portion of the oil pump housing and the cavity may receive a steel rotor. A wear-resistant coating (e.g., steel) may cover at least a portion of the peripheral wall in a region that is configured to be contacted by the steel rotor.Type: ApplicationFiled: February 3, 2017Publication date: August 9, 2018Inventors: Clifford E. MAKI, Antony George SCHEPAK, James Maurice BOILEAU
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Patent number: 10036346Abstract: An engine has a cylinder block formed by a block material and defining at least one cylinder. The block defines a lubrication circuit with fluid passages including an inlet passage, a main oil gallery, a crankshaft bearing lubrication passage, and a piston ring lubrication passage. The fluid passages are formed by continuous metal walls in contact with and surrounded by the block material. At least one of the fluid passages is curved. A method of forming a component with an internal pressurized lubrication circuit includes positioning a lost core insert in a tool, with the insert shaped to form a lubrication circuit. The lost core insert has a lost core material generally encapsulated in a continuous metal shell, and at least one curved section. Material is provided into the tool to form a body surrounding the lost core insert thereby forming a component preform.Type: GrantFiled: September 10, 2015Date of Patent: July 31, 2018Assignee: Ford Global Technologies, LLCInventors: Clifford E. Maki, Antony George Schepak, Mathew Leonard Hintzen, Mark W. Thibault
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Patent number: 9950449Abstract: A tool and a process for forming a vehicle component is provided. An insert has a lost core generally encapsulated by a cast metal shell. The insert has an anchor surface and a first locating member spaced apart therefrom, and is shaped to form a fluid passage in the vehicle component. A first die is configured to mate with the anchor surface and constrain the insert. A second die defines a first locator recess sized to receive the first locating member and constrain the insert. The first and second dies mate with one another to form the tool. The first and second dies constrain the insert in multiple degrees of freedom.Type: GrantFiled: March 2, 2015Date of Patent: April 24, 2018Assignee: Ford Global Technologies, LLCInventors: Clifford E. Maki, Antony George Schepak
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Publication number: 20180038264Abstract: An engine has a cylinder block with a deck face and at least one cylinder liner with a cylinder axis. The block has a first fluid jacket about the liner, a second fluid jacket about the liner, and a third fluid jacket about the liner. The first, second, and third fluid jackets are fluidly independent from one another and spaced apart from one another along the cylinder axis. A method for forming the engine includes using an insert to provide each of the fluid jackets. The insert has a lost core material surrounded by a metal shell.Type: ApplicationFiled: October 17, 2017Publication date: February 8, 2018Inventors: Clifford E. MAKI, Antony George SCHEPAK
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Patent number: 9797293Abstract: An engine has a cylinder block with a deck face and at least one cylinder liner with a cylinder axis. The block has a first fluid jacket about the liner, a second fluid jacket about the liner, and a third fluid jacket about the liner. The first, second, and third fluid jackets are fluidly independent from one another and spaced apart from one another along the cylinder axis. A method for forming the engine includes using an insert to provide each of the fluid jackets. The insert has a lost core material surrounded by a metal shell.Type: GrantFiled: July 30, 2015Date of Patent: October 24, 2017Assignee: Ford Global Technologies, LLCInventors: Clifford E. Maki, Antony George Schepak
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Publication number: 20170248097Abstract: Extruded cylinder liners and methods of forming the same are disclosed. The extruded engine cylinder liner may include a cylindrical body having a longitudinal axis and defining an inner surface and an outer surface. A plurality of spaced apart features may protrude from the outer surface and may extend in a direction oblique to the longitudinal axis. The method may include extruding a metal material through a die to form a cylindrical body defining an inner surface and an outer surface and a plurality of spaced apart features protruding from the outer surface. The die may be rotated about a longitudinal axis during at least a portion of the extruding step such that the features extend in a direction oblique to the longitudinal axis. The oblique features may allow parent casting material to enter channels therebetween and prevent the liner from moving in the vertical and horizontal directions.Type: ApplicationFiled: February 29, 2016Publication date: August 31, 2017Inventors: Clifford E. MAKI, Antony George SCHEPAK, Mathew Leonard HINTZEN, James Maurice BOILEAU, Mark W. THIBAULT
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Publication number: 20170175668Abstract: Engine blocks and methods of forming engine blocks are disclosed. The engine block may include a cast aluminum body and a plurality of cast-in liners. Each cast-in liner may include (a) an outer layer of 2xxx-series aluminum molecularly bonded to the cast aluminum body and (b) an inner layer directly contacting the outer layer and forming at least a portion of an engine bore. The inner layer may be a wear-resistant coating, such as a steel coating. The method may include extruding an elongated 2xxx-series aluminum extrusion having an inner cavity bounded by an inner surface and applying a wear-resistant coating to the inner surface. The extrusion may be sectioned into a plurality of cylinder liners and the cylinder liners may be into an aluminum engine block such that each cast-in liner forms at least a portion of an inner surface of an engine bore in the engine block.Type: ApplicationFiled: December 17, 2015Publication date: June 22, 2017Inventors: Antony George SCHEPAK, Clifford E. MAKI, Mathew Leonard HINTZEN
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Publication number: 20170074205Abstract: An engine has a cylinder block formed by a block material and defining at least one cylinder. The block defines a lubrication circuit with fluid passages including an inlet passage, a main oil gallery, a crankshaft bearing lubrication passage, and a piston ring lubrication passage. The fluid passages are formed by continuous metal walls in contact with and surrounded by the block material. At least one of the fluid passages is curved. A method of forming a component with an internal pressurized lubrication circuit includes positioning a lost core insert in a tool, with the insert shaped to form a lubrication circuit. The lost core insert has a lost core material generally encapsulated in a continuous metal shell, and at least one curved section. Material is provided into the tool to form a body surrounding the lost core insert thereby forming a component preform.Type: ApplicationFiled: September 10, 2015Publication date: March 16, 2017Inventors: Clifford E. MAKI, Antony George SCHEPAK, Mathew Leonard HINTZEN, Mark W. THIBAULT
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Publication number: 20170067413Abstract: A cylinder head includes an inner structural member having a plate forming a deck face of the cylinder head and forming at least one dished cylinder roof, and a plurality of cylinder head bolt columns extending from the plate. An outer member is supported by the inner structural member and forms a cooling jacket, intake ports, and exhaust ports. Passages of the cooling jacket are lined with metal walls in contact with the composite structure of the outer member. A method of forming a cylinder head includes positioning a structural insert and a lost core insert in a tool, and injecting material into the tool to form a body surrounding the structural insert and the lost core insert thereby forming a head preform. The lost core insert is shaped to form a cooling jacket and has a lost core material generally encapsulated in a metal shell.Type: ApplicationFiled: September 8, 2015Publication date: March 9, 2017Inventors: Clifford E. MAKI, Antony George SCHEPAK, Mathew Leonard HINTZEN, Mark W. THIBAULT, Christopher Donald WICKS
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Publication number: 20170030249Abstract: An engine has a cylinder block with a deck face and at least one cylinder liner with a cylinder axis. The block has a first fluid jacket about the liner, a second fluid jacket about the liner, and a third fluid jacket about the liner. The first, second, and third fluid jackets are fluidly independent from one another and spaced apart from one another along the cylinder axis. A method for forming the engine includes using an insert to provide each of the fluid jackets. The insert has a lost core material surrounded by a metal shell.Type: ApplicationFiled: July 30, 2015Publication date: February 2, 2017Inventors: Clifford E. MAKI, Antony George SCHEPAK
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Patent number: 9528464Abstract: A tool and a method of using the tool are provided for forming an engine component. The engine has a block defining a first cylinder and a second cylinder spaced apart by a bore bridge. The bore bridge defines a first cooling passage spaced apart from a deck face and extending transversely, and a second cooling passage positioned between the first passage and the deck face and extending transversely. The first and second passages are formed by a casting skin. In forming the engine component, a die is provided that defines a locator recess and at least one core. An insert is positioned into the recess on the die. The insert has a cast shell surrounding a lost core. The component is die cast with the die and the insert to form a cooling jacket. The insert is adapted to form the cooling passages for the bore bridge.Type: GrantFiled: August 11, 2014Date of Patent: December 27, 2016Assignee: Ford Global Technologies, LLCInventors: Theodore Beyer, Antony George Schepak, Mathew Leonard Hintzen, Jody Michael Slike, Venkat Nara