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).
-
Patent number: 10267258Abstract: Methods of honing a surface are disclosed. The method may include spraying a coating having an initial average bulk porosity onto an engine bore wall and honing the coating to create an intermediate honed surface. The method may then include cleaning the intermediate honed surface and honing the intermediate honed surface with a cutting force of, for example, 110-130 kgf after the cleaning step. This may create a honed surface having an average porosity greater than the initial average bulk porosity. The methods may create a honed surface having a porosity that is more porous than the initially sprayed coating. The increased porosity of the honed surface may allow for increased oil retention in, for example, engine bores.Type: GrantFiled: December 5, 2016Date of Patent: April 23, 2019Assignee: Ford Global Technologies, LLCInventors: Clifford E. Maki, Timothy George Beyer, Arup Kumar Gangopadhyay, Hamed Ghaednia, Larry Dean Elie, James Maurice Boileau
-
Patent number: 10197120Abstract: A brake component may include a body and at least one sheathed cable positioned within the body. The at least one sheathed cable may include a plurality of wires, each of the plurality of wires having a surface in sliding contact with a surface of at least one adjacent wire of the plurality of wires. During braking of the motor vehicle, relative sliding movement between the surfaces of the plurality of wires may dampen a resonant vibration of the component.Type: GrantFiled: August 3, 2016Date of Patent: February 5, 2019Assignee: FORD GLOBAL TECHNOLOGIES, LLCInventors: Yuri Anatoly Karpenko, J. Chris Oakwood, Peter Kowalow, Charles K Evans, James Maurice Boileau, Laura Dammeyer, Steven Swisher
-
Publication number: 20190017463Abstract: A method includes spraying a coating on to an engine bore surface, honing the coated surface to create a honed surface region, and cleaning the honed surface region to remove material from the surface pores. The honed surface region includes a plurality of surface pores and upper, middle, and lower regions. Cleaning the honed surface region produces upper, middle, and lower region surface porosities, with the middle region porosity being greater than at least one of the upper and lower porosities.Type: ApplicationFiled: July 11, 2017Publication date: January 17, 2019Inventors: CLIFFORD E. MAKI, LARRY DEAN ELIE, JAMES DOUGLAS ERVIN, TIMOTHY GEORGE BEYER, HAMED GHAEDNIA, JAMES MAURICE BOILEAU
-
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
-
Patent number: 10180114Abstract: A method includes spraying a coating on to an engine bore surface, honing the coated surface to create a honed surface region, and cleaning the honed surface region to remove material from the surface pores. The honed surface region includes a plurality of surface pores and upper, middle, and lower regions. Cleaning the honed surface region produces upper, middle, and lower region surface porosities, with the middle region porosity being greater than at least one of the upper and lower porosities.Type: GrantFiled: July 11, 2017Date of Patent: January 15, 2019Assignee: FORD GLOBAL TECHNOLOGIES, LLCInventors: Clifford E. Maki, Larry Dean Elie, James Douglas Ervin, Timothy George Beyer, Hamed Ghaednia, James Maurice Boileau
-
Publication number: 20180298964Abstract: 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: ApplicationFiled: April 12, 2017Publication date: October 18, 2018Inventors: Yuri A. Karpenko, David Allen, James Maurice Boileau, J. Chris Oakwood, Peter Kowalow, Laura Dammeyer, Steven Swisher, Robert Gordon Rentsschler
-
Publication number: 20180287316Abstract: 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: ApplicationFiled: March 30, 2017Publication date: October 4, 2018Applicant: FORD GLOBAL TECHNOLOGIES, LLCInventors: Brian Joseph Robert, James Maurice Boileau, Thomas P. Brackett, III
-
Patent number: 10082187Abstract: A brake rotor includes an outer surface; first and second opposing braking surfaces, each bounded by the outer surface to form first and second opposing braking surface edges. A plurality of concentric grooves are formed on the first and/or second braking surfaces.Type: GrantFiled: December 22, 2014Date of Patent: September 25, 2018Assignee: Ford Global Technologies, LLCInventors: David Alan Stephenson, James Maurice Boileau, Timothy J. Potter, David Garrett Coffman
-
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
-
Dry friction damped mechanical and structural metal components and methods of manufacturing the same
Patent number: 10060495Abstract: A method and system for increasing damping capacity in cast metal parts by utilizing dry friction between individual wires of a sheathed rope is disclosed. The rope is embedded into the part during casting. Sheathing the ropes in a thin layer of the same metal as the casting prevents molten metal from infiltrating individual wires during casting, thus allowing inter-wire friction during the part vibration. There are two ways to distribute the ropes within a part during casting. The first way is to distribute the ropes uniformly across an entire part whereby damping capacity of the metal part increases uniformly as well. The second way of distributing the ropes is to spatially distribute them according to a pattern to increase the damping capacity only in the part regions that have the highest vibration amplitudes or stress during system vibration. Both methods of distribution may be combined in a single part.Type: GrantFiled: September 15, 2016Date of Patent: August 28, 2018Assignee: Ford Global Technologies, LLCInventors: James Maurice Boileau, Yuri Anatoly Karpenko, J. Chris Oakwood, Peter Kowalow, Laura Dammeyer, Steven Swisher -
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
-
Publication number: 20180156155Abstract: Methods of honing a surface are disclosed. The method may include spraying a coating having an initial average bulk porosity onto an engine bore wall and honing the coating to create an intermediate honed surface. The method may then include cleaning the intermediate honed surface and honing the intermediate honed surface with a cutting force of, for example, 110-130 kgf after the cleaning step. This may create a honed surface having an average porosity greater than the initial average bulk porosity. The methods may create a honed surface having a porosity that is more porous than the initially sprayed coating. The increased porosity of the honed surface may allow for increased oil retention in, for example, engine bores.Type: ApplicationFiled: December 5, 2016Publication date: June 7, 2018Inventors: Clifford E. MAKI, Timothy George BEYER, Arup Kumar GANGOPADHYAY, Hamed GHAEDNIA, Larry Dean ELIE, James Maurice BOILEAU
-
DRY FRICTION DAMPED MECHANICAL AND STRUCTURAL METAL COMPONENTS AND METHODS OF MANUFACTURING THE SAME
Publication number: 20180073588Abstract: A method and system for increasing damping capacity in cast metal parts by utilizing dry friction between individual wires of a sheathed rope is disclosed. The rope is embedded into the part during casting. Sheathing the ropes in a thin layer of the same metal as the casting prevents molten metal from infiltrating individual wires during casting, thus allowing inter-wire friction during the part vibration. There are two ways to distribute the ropes within a part during casting. The first way is to distribute the ropes uniformly across an entire part whereby damping capacity of the metal part increases uniformly as well. The second way of distributing the ropes is to spatially distribute them according to a pattern to increase the damping capacity only in the part regions that have the highest vibration amplitudes or stress during system vibration. Both methods of distribution may be combined in a single part.Type: ApplicationFiled: September 15, 2016Publication date: March 15, 2018Inventors: James Maurice Boileau, Yuri Anatoly Karpenko, J. Chris Oakwood, Peter Kowalow, Laura Dammeyer, Steven Swisher -
Publication number: 20170260926Abstract: 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: ApplicationFiled: March 9, 2016Publication date: September 14, 2017Inventors: CLIFFORD E. MAKI, LARRY DEAN ELIE, TIMOTHY GEORGE BEYER, ARUP KUMAR GANGOPADHYAY, HAMED GHAEDNIA, JAMES MAURICE BOILEAU
-
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
-
Patent number: 9719461Abstract: An engine includes a cylinder block defining at least one main bearing bulkhead adjacent to a cylinder, and a crankshaft rotatably housed within the block by a main bearing. A bulkhead insert has a cap portion, and an insert portion provided within the bulkhead. The insert portion has having first and second end regions connected by first and second straps. Each strap having a flanged beam cross section. The first and second ends of the insert portion are configured to connect a main bearing cap column to a cylinder head column. Each of the first and second end regions define at least one protrusion having a surface substantially normal to engine combustion and reactive loads. The cap portion is configured to mate with the first end region at the main bearing cap column and support the main bearing.Type: GrantFiled: February 12, 2015Date of Patent: August 1, 2017Assignee: Ford Global Technologies, LLCInventors: Clifford E. Maki, Jeffrey Eliot Chottiner, Rick L. Williams, Mark W. Thibault, James Douglas Ervin, James Maurice Boileau, Bryan McKeough
-
Publication number: 20170152590Abstract: 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: ApplicationFiled: February 9, 2017Publication date: June 1, 2017Inventors: Nia R. HARRISON, S. George LUCKEY, JR., James Maurice BOILEAU, Aindrea McKelvey CAMPBELL, Amanda Kay FREIS
-
Patent number: 9611526Abstract: 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 25, 2014Date of Patent: April 4, 2017Assignee: Ford Global Technologies, LLCInventors: Nia R. Harrison, S. George Luckey, Jr., James Maurice Boileau, Aindrea McKelvey Campbell, Amanda Kay Freis
-
Publication number: 20160341269Abstract: A brake component may include a body and at least one sheathed cable positioned within the body. The at least one sheathed cable may include a plurality of wires, each of the plurality of wires having a surface in sliding contact with a surface of at least one adjacent wire of the plurality of wires. During braking of the motor vehicle, relative sliding movement between the surfaces of the plurality of wires may dampen a resonant vibration of the component.Type: ApplicationFiled: August 3, 2016Publication date: November 24, 2016Applicant: FORD GLOBAL TECHNOLOGIES, LLCInventors: Yuri Anatoly KARPENKO, J. Chris Oakwood, Peter KOWALOW, Charles K. EVANS, James Maurice BOILEAU, Laura DAMMEYER, Steven SWISHER
-
Publication number: 20160319417Abstract: Methods of applying a corrosion protection layer and components protected thereby are disclosed. In one embodiment, a corrosion-resistant assembly is provided including a first metal component joined to a second metal component, a joint interface between the first and second components, and a corrosion protection layer covering at least a portion of the joint interface, the corrosion protection layer including aluminum or zinc. The corrosion protection layer (CPL) may be applied by a spraying process, such as thermal spraying. The CPL may be a non-structural coating and may be formed of commercially pure aluminum (e.g., at least 99 wt. %). The CPL may form a seal between two components at the joint interface, for example, when components are joined using a hem-lock. The CPL may also be applied to newly machined surfaces, such as cut surfaces and punch surfaces to prevent or reduce corrosion.Type: ApplicationFiled: April 28, 2015Publication date: November 3, 2016Inventors: James Maurice BOILEAU, Janice Lisa TARDIFF, Matthew John ZALUZEC