Patents by Inventor Josh Kelman
Josh Kelman 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: 6776944Abstract: A method for mounting interior vehicle trim parts in which two trim parts are supported adjacent one another and in which a bead of buffer material is disposed between mating surfaces of the two trim parts. The bead is included to reduce noises such as buzzes, squeaks and rattles produced by contact and relative motion between the first and second trim parts at their mating surfaces. The bead is mechanically locked into a recess in one of the mating surfaces by forming a recess in the mating surface then applying buffer material in the recess. The buffer material is applied in such a way as to form the bead. The bead is allowed to mechanically connect to the first trim part as a result of the hardening of the buffer material within the recess.Type: GrantFiled: May 28, 1999Date of Patent: August 17, 2004Assignee: Textron Automotive Company Inc.Inventors: Josh Kelman, Brian Pour, Ed Shortridge
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Publication number: 20010033042Abstract: A method for assembling interior vehicle trim parts including panels and components in which two trim parts are disposed adjacent one another and in which a bead of buffer material is disposed between mating surfaces of the two trim parts. The bead is included to reduce noises such as buzzes, squeaks and rattles produced by contact and relative motion between the first and second trim parts at their mating surfaces. The bead is mechanically locked into a recess in one of the mating surfaces. The bead is mechanically locked to a mating surface by forming a recess in the mating surface then applying buffer material in the recess. The buffer material is applied in such a way as to form a bead of buffer material on the mating surface. The bead is allowed to mechanically connect to the first trim part as a result of the hardening of the buffer material within the recess.Type: ApplicationFiled: May 28, 1999Publication date: October 25, 2001Inventors: JOSH KELMAN, BRIAN POUR, ED SHORTRIDGE
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Patent number: 6127021Abstract: According to one aspect of the invention, a multi-layer automotive interior trim panel (10) comprises a decorative covering layer (12) and a supportive substrate layer (16). The substrate layer (16) is comprised of a rigid material formed into a predetermined shape for supporting the covering layer. The trim panel also includes an intermediate layer (18) disposed between the covering layer and the supportive substrate layer comprised of cushioning material. The intermediate layer includes a mat (20) of polymeric fibers, with the mat having a plurality of indentations (24) to provide a cushioning effect. A corresponding method for producing the interior trim panel having the three layers includes several steps. The first step is heating the cushion layer (18) to a predetermined temperature. The second step is melting a portion of the polymeric fibers in the cushion layer. The third step is stamping the cushion layer to form the plurality of indentations (24).Type: GrantFiled: July 1, 1998Date of Patent: October 3, 2000Assignee: Textron Automotive Company, Inc.Inventor: Josh Kelman
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Patent number: 5843365Abstract: A preform of complex three-dimensional shape is prepared by a directed fiber preforming process in which a flow of chopped fibers are drawn by vacuum against a foraminous screen having a shape corresponding to that of preform to be made. The screen has depressed regions that are susceptible to excessive build-up of the chopped fibers. To counteract the build-up in these areas, a baffling system is provided behind the screen having baffle plates which are extendable into and out of blocking engagement with the backside of the problem depressed regions to govern the vacuum draw and hence the deposit and build-up of fibers across the depressed regions.Type: GrantFiled: January 6, 1997Date of Patent: December 1, 1998Assignee: Textron Automotive Company Inc.Inventors: David R. Pinson, Robert A. Hames, Josh Kelman
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Patent number: 5823602Abstract: A motor vehicle body has an instrument panel construction that includes a structural instrument panel carrier of plastic material for mounting instrument panel components. The carrier is attached to side pillars located at a juncture of passenger and engine compartments so as to form a cross beam. The instrument panel construction has its external appearance determined by adding facial instrument panel coverings to the instrument panel carrier after the instrument panel components are mounted on the instrument panel carrier. The structural instrument panel carrier may also be integrated with a front of dash (FOD) panel that may be composed of the same material and that provides a second cross beam.Type: GrantFiled: July 25, 1994Date of Patent: October 20, 1998Assignee: Davidson Textron Inc.Inventors: Josh Kelman, John Gray, Michael Gorman
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Patent number: 5804511Abstract: A structural reaction injection molded motor vehicle bumper beam comprises a preform formed of layers of interlaced glass fibers and chopped glass fibers wherein most of the interlaced fibers are oriented longitudinally of the bumper beam. A two-component, non-filled reaction injection molding polymeric/pure polyurethane based resin with a neat elongation in excess of about 50% bonds the fiberglass layers together in a composite bumper beam structure wherein the fiberglass provides substantial strength and stiffness and the highly compliant resin allows extensive beam deflection without catastrophic cracking to enable the bumper beam without other assistance to absorb sufficient energy in repeated impacts to meet in-service requirements.Type: GrantFiled: April 10, 1996Date of Patent: September 8, 1998Assignee: Davidson Textron Inc.Inventors: Josh Kelman, Gullmar V. Nelson
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Patent number: 5733631Abstract: A soft panel has a layer formed from thermoplastic fiber clusters comprised of a very high percentage of crooked matrix fibers and a very low percentage of crooked binder fibers with a lower melt temperature and wherein the fibers have a plurality of bends that entangle the fibers together in the clusters. The fiber clusters are blown onto a first foraminous screen that defines a retainer side of the fiber layer and through which air is being drawn. A second foraminous screen is then added to compact the fiber clusters and define a skin side of the fiber layer. Hot air is then circulated through the compacted fiber clusters to melt the binder fibers to fuse the matrix fibers together where they touch to form an integral soft springy fiber cluster layer to the shape of the screens.Type: GrantFiled: April 2, 1996Date of Patent: March 31, 1998Assignee: Davidson Textron Inc.Inventor: Josh Kelman
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Patent number: 5681519Abstract: A composite plastic article having a foam core between reinforced plastic skin layers is made by placing foam spacers, a lower reinforcement preform, a foam core and an upper reinforcement preform on a lower mold part. An upper mold part is then mated with the lower mold part in a partially closed position to form a sealed mold cavity containing the foam spacers, reinforcement preforms and the foam core with fill spaces provided adjacent exterior surfaces of the reinforcement preforms. A low viscosity resin is then injected into the fill spaces while the mold parts are held in the partially closed position. The mold parts are then moved to a fully closed position. This distributes the resin across the exterior surfaces and forces the resin into the preforms so that the resin thoroughly penetrates throughout the interstices of the preforms and bonds to the foam core.Type: GrantFiled: January 17, 1995Date of Patent: October 28, 1997Assignee: Davidson Textron Inc.Inventor: Josh Kelman
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Patent number: 5679296Abstract: An automotive interior trim part (10) is made by molding a substrate retainer layer (16), forming a skin layer (12) and forming an intermediate layer (14). The intermediate layer (14) is formed from a plurality of clusters of entangled high melt and low melt kinked fibers of polyethylene terephthalate (PET). The PET layer is blown into a partially closed mold that has the skin and retainer positioned in each mold die. The mold undergoes induced vibrations to promote tightening of the packed clusters. The mold is then fully closed to compress the PET fibers into full density. Heated air is then blown into the mold to soften the low melt fibers to adhere them to the retainer layer and skin. Cool air is then blown into the mold to resolidfy the clusters and form the intermediate layer into its molded shape.Type: GrantFiled: September 29, 1995Date of Patent: October 21, 1997Assignee: Davidson Textron, Inc.Inventors: Josh Kelman, Stephen N. Roberts, William W. Knight, Randy Reed, David R. Pinson, Alfred F. Brault
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Patent number: 5660908Abstract: A recyclable automotive headliner consists 100% of polyethylene terephthalate (PET) material and includes reverse ribs of varying density of PET fibers filled with reinforcements of full density PET material. A method of manufacturing such headliners includes forming the reverse ribs in the PET fibers and either preforming the full density reinforcements and bonding them between the ribs or forming the ribs and then injecting molten full density PET material therebetween.Type: GrantFiled: March 22, 1996Date of Patent: August 26, 1997Assignee: Davidson Textron Inc.Inventors: Josh Kelman, Richard D. Rhodes
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Patent number: 5556153Abstract: An instrument panel assembly includes an instrument panel carrier, a top panel and a front of dash panel of one-piece molded plastic construction. The top panel includes an upper housing part and the front of dash panel includes a lower housing part that cooperatively form a housing for components of a heating, ventilating and air conditioning system when the top and front close-out panels are attached to the instrument panel carrier. Each panel also cooperates with the instrument panel to form an air distribution duct for the heating, ventilating and air conditioning system that communicates with the housing formed by the two panels.Type: GrantFiled: October 14, 1994Date of Patent: September 17, 1996Assignee: Davidson Textron Inc.Inventors: Josh Kelman, Lee E. Gridley
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Patent number: 5536341Abstract: A soft panel has a layer formed from thermoplastic fiber clusters comprised of a very high percentage of crooked matrix fibers and a very low percentage of crooked binder fibers with a lower melt temperature and wherein the fibers have a plurality of bends that entangle the fibers together in the clusters. The fiber clusters are blown onto a first foraminous screen that defines a retainer side of the fiber layer and through which air is being drawn. A layer of thermoplastic powder is sprayed onto a thermoplastic veil draped over the fiber cluster layer while the latter remains on the first screen and air is drawn through this screen and the veil to retain the powder layer in place. A hot shell skin tool is then applied to the powder to form a flexible skin fused to the fiber cluster layer. The fiber cluster layer with the flexible skin joined thereto is then adhered on its retainer side to a preformed rigid retainer to complete the panel.Type: GrantFiled: September 1, 1994Date of Patent: July 16, 1996Assignee: Davidson Textron Inc.Inventor: Josh Kelman
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Patent number: 5520758Abstract: A process for producing a reinforced plastic motor vehicle bumper includes the steps of placing a woven roving (17) on a center section of a preform screen (10) that is retained by a vacuum draw from a suction fan (16). Chopped glass fibers (20) and a curable binder are sprayed onto the preform screen and woven roving. A second layer (22) of woven roving is placed onto the center section of chopped glass and first layer (17) of woven roving. Either the excess trim (39) is trimmed by a cutting die (50) before the preform is cured or the die is first cured and then the excess trim is trimmed by a cutter using a plastic base (35) in the screen that circumscribes the contoured section of the preform screen.Type: GrantFiled: January 12, 1995Date of Patent: May 28, 1996Assignee: Davidson Textron Inc.Inventors: Josh Kelman, Robert Hames
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Patent number: 5413750Abstract: A process for producing a preform includes the steps of retaining a glass fiber fabric (40) on a foraminous screen (14) by use of a vacuum draw and depositing chopped glass fibers (19) onto the glass fiber fabric with a binder that cures in place. The vacuum draw retains the deposited materials in place until the binder is cured.Type: GrantFiled: April 8, 1992Date of Patent: May 9, 1995Assignee: Davidson Textron Inc.Inventors: Josh Kelman, Robert Hames
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Patent number: 5370417Abstract: An instrument panel for an automotive vehicle includes a substructure that extends across the width of an automotive vehicle passenger compartment and is secured to side pillars of an automotive vehicle body. A pair of laterally spaced knee bolsters each include a retainer that has a rearwardly facing wall that is located at knee height, and a pair of integrally attached, vertically spaced struts that are attached to a lower channel of the substructure to form a first box structure for absorbing impact energy. A front channel is disposed in front of the lower channel and securely attached to the substructure of the instrument panel. The attached channels provide a cross car duct for wiring or air distribution and a second box structure for absorbing energy when the knee bolster is impacted in a vehicle collision.Type: GrantFiled: April 18, 1994Date of Patent: December 6, 1994Assignee: Davidson Textron Inc.Inventors: Josh Kelman, John Gray, John Ribick, Dennis Marion
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Patent number: 5364159Abstract: A motor vehicle body has an instrument panel construction that includes a structural instrument panel carrier of plastic material for mounting instrument panel components. The carrier is attached to side pillars located at a juncture of passenger and engine compartments so as to form a cross beam. The instrument panel construction has its external appearance determined by adding facial instrument panel coverings to the instrument panel carrier after the instrument panel components are mounted on the instrument panel carrier. The structural instrument panel carrier may also be integrated with a front of dash (FOD) panel that may be composed of the same material and that provides a second cross beam.Type: GrantFiled: June 15, 1993Date of Patent: November 15, 1994Assignee: Davidson Textron Inc.Inventors: Josh Kelman, John Gray, Michael Gorman
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Patent number: 5354114Abstract: An automotive vehicle body has an integrated cross car structural duct cluster that is a composite that is connected to side pillars located on opposite sides of the vehicle body. The composite acts as a cross beam and provides four ducts that extend across the width of the vehicle body. Three ducts are related to the HVAC system of the vehicle and the fourth is a wiring duct. Five variations are disclosed. In two the composite comprises steel rods embedded in a molded plastic body. In the other three the composite comprises a steel plate that is attached to a molded plastic body.Type: GrantFiled: June 21, 1993Date of Patent: October 11, 1994Assignee: Davidson Textron Inc.Inventors: Josh Kelman, John Gray
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Patent number: 5336455Abstract: A process for producing a motor vehicle bumper includes the steps of depositing chopped glass fibers (19) and a curable binder (24) to a center section (38) of a preform (11) that is retained on a preform screen (14) by a vacuum draw from a suction fan (15). A ratio of shredded structural reinforced injected molded plastic (23) and glass fiber (19) is sprayed to form end sections (41) and flanges (39) of the preform (11) along with binder (24). The preform (11) is then cured on the screen (14).Type: GrantFiled: October 8, 1992Date of Patent: August 9, 1994Assignee: Davidson Textron Inc.Inventor: Josh Kelman
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Patent number: 5328494Abstract: A process for producing a preform (44) includes pretreating roving by submerging it in a tank (18) and cooling the binder (20) on the glass fibers before the glass fibers are chopped. The fibers and solidified binder are then chopped and deposited onto a preform screen (32). Heat is applied to soften the binder that is on the chopped glass fibers and cooled to set the binder and form the preform on the screen.Type: GrantFiled: April 8, 1992Date of Patent: July 12, 1994Assignee: Davidson Textron Inc.Inventors: Josh Kelman, Robert Hames
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Patent number: 5248551Abstract: A process for producing a reinforced plastic motor vehicle bumper includes the steps of placing a woven roving (17) on a center section of a preform screen (10) that is retained by a vacuum draw from a suction fan (16). Chopped glass fibers (20) and a curable binder are sprayed onto the preform screen and woven roving. A second layer (22) of woven roving is placed onto the center section of chopped glass and first layer (17) of woven roving. Either the excess trim (39) is trimmed by a cutting die (50) before the preform is cured or the die is first cured and then the excess trim is trimmed by a cutter using a plastic base (35) in the screen that circumscribes the contoured section of the preform screen.Type: GrantFiled: April 29, 1992Date of Patent: September 28, 1993Assignee: Davidson Textron Inc.Inventors: Josh Kelman, Robert Hames