Patents by Inventor James Maurice Boileau
James Maurice Boileau 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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Publication number: 20230187726Abstract: Battery pack designs are provided for use in electrified vehicles. Exemplary battery packs may include a battery array that includes one or more interconnected array frames. A split thermal fin may be held within the one or more array frames. The proposed designs of the split thermal fin enable a reduction of the amount of thermal interface material required between the thermal fin and a support structure (e.g., a heat exchanger plate) of the battery pack.Type: ApplicationFiled: February 8, 2023Publication date: June 15, 2023Inventors: Rajaram Subramanian, Dave Moschet, James Maurice Boileau, Shamsuddin A. Syed, Suriyaprakash Ayyangar Janarthanam
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Patent number: 11581595Abstract: This disclosure details exemplary battery pack designs for use in electrified vehicles. Exemplary battery packs may include a battery array that includes one or more interconnected array frames. A split thermal fin may be held within the one or more array frames. The proposed designs of the split thermal fin enable a reduction of the amount of thermal interface material required between the thermal fin and a support structure (e.g., a heat exchanger plate) of the battery pack.Type: GrantFiled: September 2, 2020Date of Patent: February 14, 2023Assignee: FORD GLOBAL TECHNOLOGIES, LLCInventors: Rajaram Subramanian, Dave Moschet, James Maurice Boileau, Shamsuddin A. Syed, Suriyaprakash Ayyangar Janarthanam
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Patent number: 11539096Abstract: A battery assembly includes, among other things, an enclosure having a floor, and battery cell frames disposed along an axis within the enclosure. Each of the battery cell frames includes a frame foot that projects laterally outward. An endplate is at an axial end of the battery cell frames. The endplate includes an endplate retention flange that projects laterally outward to laterally overlap with a portion of the retention member. A retention member extends axially alongside the battery cell frames. The retention member includes a lip that projects laterally inward across the frame feet such that the frame feet are held between the lip and the floor. An axial end portion of the retention member is secured directly to the endplate retention flange.Type: GrantFiled: August 3, 2020Date of Patent: December 27, 2022Assignee: Ford Global Technologies, LLCInventors: Shamsuddin A. Syed, Rajaram Subramanian, Ihab Grace, James Maurice Boileau
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Publication number: 20220069378Abstract: This disclosure details exemplary battery pack designs for use in electrified vehicles. Exemplary battery packs may include a battery array that includes one or more interconnected array frames. A split thermal fin may be held within the one or more array frames. The proposed designs of the split thermal fin enable a reduction of the amount of thermal interface material required between the thermal fin and a support structure (e.g., a heat exchanger plate) of the battery pack.Type: ApplicationFiled: September 2, 2020Publication date: March 3, 2022Inventors: Rajaram Subramanian, Dave Moschet, James Maurice Boileau, Shamsuddin A. Syed, Suriyaprakash Ayyangar Janarthanam
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Publication number: 20220037630Abstract: A battery assembly includes, among other things, an enclosure having a floor, and battery cell frames disposed along an axis within the enclosure. Each of the battery cell frames includes a frame foot that projects laterally outward. An endplate is at an axial end of the battery cell frames. The endplate includes an endplate retention flange that projects laterally outward to laterally overlap with a portion of the retention member. A retention member extends axially alongside the battery cell frames. The retention member includes a lip that projects laterally inward across the frame feet such that the frame feet are held between the lip and the floor. An axial end portion of the retention member is secured directly to the endplate retention flange.Type: ApplicationFiled: August 3, 2020Publication date: February 3, 2022Inventors: Shamsuddin A. Syed, Rajaram Subramanian, Ihab Grace, James Maurice Boileau
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Publication number: 20220017031Abstract: Battery pack designs for use in electrified vehicles may include a polymer-based enclosure having features for sealing external joints, retaining components inside the battery pack, securing electrical and coolant lines to the polymer-based enclosure, etc. The proposed designs reduce the number of overall parts in assembly, such as fasteners and brackets, and simplify the overall battery pack manufacturing and assembly processes.Type: ApplicationFiled: July 15, 2021Publication date: January 20, 2022Inventors: Thomas Edward SMITH, Patrick Daniel Maguire, Kanchana PERUMALLA, Mohammadreza EFTEKHARI, Saravanan PARAMASIVAM, James Maurice BOILEAU
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Publication number: 20210184195Abstract: This disclosure details exemplary battery pack designs for use in electrified vehicles. An exemplary battery pack may include a battery system and a passive thermal suppression material system positioned about at least a portion of the battery system. The passive thermal suppression material system is configured to release a thermal suppression material during certain battery thermal events. The thermal suppression material prevents or delays thermal runaway inside the battery pack.Type: ApplicationFiled: December 17, 2019Publication date: June 17, 2021Inventors: Mohammadreza EFTEKHARI, James Maurice BOILEAU, Patrick Daniel MAGUIRE
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Patent number: 10907569Abstract: Methods and systems are provided for filling surface pores of a cylinder inner surface coating with one or more fill materials to provide desired material and performance properties. In one example, a cylinder for an engine includes an inner surface including a coating having a plurality of surface pores, at least a portion of the plurality of surface pores filled with one or more fill materials, the one or more fill materials configured to decrease friction, increase tribofilm formation, adjust heat transfer, decrease material deposit, and/or decrease run-in duration.Type: GrantFiled: June 19, 2019Date of Patent: February 2, 2021Assignee: Ford Global Technologies, LLCInventors: Larry Dean Elie, Hamed Ghaednia, Clifford E. Maki, Timothy George Beyer, Arup Kumar Gangopadhyay, James Maurice Boileau
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Publication number: 20200400093Abstract: Methods and systems are provided for filling surface pores of a cylinder inner surface coating with one or more fill materials to provide desired material and performance properties. In one example, a cylinder for an engine includes an inner surface including a coating having a plurality of surface pores, at least a portion of the plurality of surface pores filled with one or more fill materials, the one or more fill materials configured to decrease friction, increase tribofilm formation, adjust heat transfer, decrease material deposit, and/or decrease run-in duration.Type: ApplicationFiled: June 19, 2019Publication date: December 24, 2020Inventors: Larry Dean Elie, Hamed Ghaednia, Clifford E. Maki, Timothy George Beyer, Arup Kumar Gangopadhyay, James Maurice Boileau
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Patent number: 10746128Abstract: Engine blocks and methods of forming the same are disclosed. The engine block may comprise a body including at least one cylindrical engine bore wall having a longitudinal axis and including a coating extending along the longitudinal axis and having a coating thickness. The coating may have a middle region and first and second end regions, and a plurality of pores may be dispersed within the coating thickness. The middle region may have a different average porosity than one or both of the end regions. The method may include spraying a first porosity coating in a middle longitudinal region of the bore and spraying a second porosity coating in one or more end regions of the bore. The first porosity may be greater than the second porosity and the first and second porosities may be formed during the spraying steps. The pores may act as wells for lubricant.Type: GrantFiled: November 18, 2019Date of Patent: August 18, 2020Assignee: Ford Motor CompanyInventors: Clifford E Maki, Larry Dean Elie, Timothy George Beyer, Arup Kumar Gangopadhyay, Hamed Ghaednia, James Maurice Boileau
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Patent number: 10734629Abstract: A vehicle traction battery assembly including a battery cell, a busbar, and a thermal spray is provided. The battery cell may include a terminal having an angled taper upper portion extending therefrom. The busbar may define a through-hole having a taper defining an angle substantially opposite of the angled taper upper portion such that a cavity is defined therebetween when the terminal extends through the through-hole. The thermal spray may be deposited within the cavity to secure the busbar to the terminal. The thermal spray may be formed from a metallic powder selected to include particles that deform and connect when accelerated to a speed of approximately 500 mph or more to join the particles and form a bond securing the terminal to the busbar. The particles of the metallic powder may be iron, copper, aluminum, nickel, iron, or magnesium.Type: GrantFiled: February 23, 2018Date of Patent: August 4, 2020Assignee: Ford Global Technologies, LLCInventors: Brian Joseph Robert, Thomas P. Brackett, James Maurice Boileau
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Patent number: 10640876Abstract: A battery pack includes a pouch cell having electrode tabs extending therefrom, each of the tabs defining a plurality of perforations, a busbar including a plurality of raised portions in contact with and protruding through the perforations, and an agglomeration of mechanically bound solid metal particles overlaying the raised portions to mechanically bind and electrically connect the tabs to the busbar.Type: GrantFiled: March 30, 2017Date of Patent: May 5, 2020Assignee: FORD GLOBAL TECHNOLOGIES, LLCInventors: Brian Joseph Robert, James Maurice Boileau, Thomas P. Brackett, III
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Publication number: 20200102906Abstract: Engine blocks and methods of forming the same are disclosed. The engine block may comprise a body including at least one cylindrical engine bore wall having a longitudinal axis and including a coating extending along the longitudinal axis and having a coating thickness. The coating may have a middle region and first and second end regions, and a plurality of pores may be dispersed within the coating thickness. The middle region may have a different average porosity than one or both of the end regions. The method may include spraying a first porosity coating in a middle longitudinal region of the bore and spraying a second porosity coating in one or more end regions of the bore. The first porosity may be greater than the second porosity and the first and second porosities may be formed during the spraying steps. The pores may act as wells for lubricant.Type: ApplicationFiled: November 18, 2019Publication date: April 2, 2020Inventors: Clifford E MAKI, Larry Dean ELIE, Timothy George BEYER, Arup Kumar GANGOPADHYAY, Hamed GHAEDNIA, James Maurice BOILEAU
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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: 10480448Abstract: Engine blocks and methods of forming the same are disclosed. The engine block may comprise a body including at least one cylindrical engine bore wall having a longitudinal axis and including a coating extending along the longitudinal axis and having a coating thickness. The coating may have a middle region and first and second end regions, and a plurality of pores may be dispersed within the coating thickness. The middle region may have a different average porosity than one or both of the end regions. The method may include spraying a first porosity coating in a middle longitudinal region of the bore and spraying a second porosity coating in one or more end regions of the bore. The first porosity may be greater than the second porosity and the first and second porosities may be formed during the spraying steps. The pores may act wells for lubricant.Type: GrantFiled: March 9, 2016Date of Patent: November 19, 2019Assignee: Ford Motor CompanyInventors: Clifford E. Maki, Larry Dean Elie, Timothy George Beyer, Arup Kumar Gangopadhyay, Hamed Ghaednia, James Maurice Boileau
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Patent number: 10450639Abstract: In at least one embodiment, an assembly is provided comprising a first member including a 6xxx series aluminum alloy heat treated to have a yield strength of at least 200 MPa and an r/t (bendability) ratio of up to 0.4. One or more members may be secured to the first member with a rivet (e.g., a self-piercing rivet). The heat treated alloy may have a yield strength of at least 260 MPa and may have a bendability ratio of up to 0.3. A method of forming an assembly is also provided, including heat treating a 6xxx series aluminum alloy to produce an alloy having a yield strength of at least 200 MPa and an r/t (bendability) ratio of up to 0.4 and riveting a member including the heat treated alloy to one or more additional members.Type: GrantFiled: February 9, 2017Date of Patent: October 22, 2019Assignee: FORD GLOBAL TECHNOLOGIES, LLCInventors: Nia R. Harrison, S. George Luckey, Jr., James Maurice Boileau, Aindrea McKelvey Campbell, Amanda Kay Freis
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Publication number: 20190267600Abstract: A vehicle traction battery assembly including a battery cell, a busbar, and a thermal spray is provided. The battery cell may include a terminal having an angled taper upper portion extending therefrom. The busbar may define a through-hole having a taper defining an angle substantially opposite of the angled taper upper portion such that a cavity is defined therebetween when the terminal extends through the through-hole. The thermal spray may be deposited within the cavity to secure the busbar to the terminal. The thermal spray may be formed from a metallic powder selected to include particles that deform and connect when accelerated to a speed of approximately 500 mph or more to join the particles and form a bond securing the terminal to the busbar. The particles of the metallic powder may be iron, copper, aluminum, nickel, iron, or magnesium.Type: ApplicationFiled: February 23, 2018Publication date: August 29, 2019Applicant: Ford Global Technologies, LLCInventors: Brian Joseph Robert, Thomas P. Brackett, James Maurice Boileau
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Patent number: 10392685Abstract: An alloy composite material comprising an aluminum alloy layer and a thermal spray alloy layer of 20 to 40% Mn and 47 to 76% Fe by weight in overlaying contact with the aluminum alloy layer. An alloy composite material comprising an aluminum alloy layer or base layer and a thermal spray alloy layer of 20 to 40% Mn and 47 to 76% Fe by weight in overlaying contact with the aluminum alloy layer or base layer. The aluminum alloy layer or base layer and the thermal spray alloy layer have a mechanical compatibility to each other of 20-60 MPa as determined using tests specified by ASTM-C633 test. A process of thermal spraying comprising providing a base layer and a feed stock alloy of 20 to 40% Mn and 47 to 76% Fe and thermally spraying the feed stock alloy onto the base layer to form an alloy composite material.Type: GrantFiled: October 31, 2013Date of Patent: August 27, 2019Assignees: THE REGENTS OF THE UNIVERSITY OF MICHIGAN, FORD GLOBAL TECHNOLOGIES, LLCInventors: James Maurice Boileau, Timothy J. Potter, Paul George Sanders, Matthew John Zaluzec, Pravansu Sekhar Mohanty, Vikram Varadarrajan
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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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Patent number: 10309469Abstract: A friction damping cast component and method of production are disclosed. The components may be rotary, such as a cast brake rotor, or may be non-rotary, such as a cast suspension part or a cast engine block. Regardless of the type of component, a two-part vibration-damping insert having a thin metal core and a thin metal sheath is provided. The sheath fully encompasses the core in such a way that a dry sliding friction contact develops at their interfaces. The outer surface of the sheath with the metal core inside is rigidly bonded to the cast material that surrounds it during the casting process. The sheath surfaces may have a number of openings that allow a limited infiltration of molten cast iron material just inside the immediate vicinity of the sheath openings for spot rigid bonding between the surrounding cast material and the insert surfaces during casting.Type: GrantFiled: April 12, 2017Date of Patent: June 4, 2019Assignee: Ford Global Technologies, LLCInventors: Yuri A. Karpenko, David Allen, James Maurice Boileau, J. Chris Oakwood, Peter Kowalow, Laura Dammeyer, Steven Swisher, Robert Gordon Rentschler