Patents by Inventor Kevin A. McCullough
Kevin A. McCullough 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).
-
Publication number: 20140053999Abstract: A method of metal injection molding on a plastics injection molding machine having a heated barrel with an increasing temperature gradient is disclosed. The method comprises the steps of providing a metal alloy feedstock including a first metal alloy with a first melting point and a second metal alloy with a second melting point that is higher than the first melting point, the first metal alloy and the second metal alloy providing a gradient in composition of solids to liquids paralleling the temperature gradient of the heated barrel, feeding the first metal alloy and the second metal alloy into the plastics injection molding machine, heating the first metal alloy and the second metal alloy within the plastics injection molding machine to about 500-700° F./260-372° C.; and forming an equilibrium of about 5% to about 30% solids to liquids between the first metal alloy and second metal alloy within the heated barrel.Type: ApplicationFiled: October 25, 2013Publication date: February 27, 2014Applicant: COOL POLYMERS, INC.Inventors: Kevin A. McCullough, James D. Miller
-
Patent number: 8591804Abstract: A method of metal injection molding on an injection molding machine having a heated barrel with an increasing temperature gradient is disclosed. A first step includes providing a metal alloy feedstock including a first component having a first melting point and a second component having a second melting point that is higher than the first melting point, the first melting point and the second melting point selected to match the temperature gradient of the heated barrel of the injection molding machine. A second step includes feeding the metal alloy feedstock into the injection molding machine. A third step includes melting the metal alloy feedstock within the heated barrel of the injection molding machine. A fourth step includes maintaining the percentage of solids to liquids in the metal alloy feedstock of the first component and second component within a processable range of about 5% to about 30%.Type: GrantFiled: May 31, 2011Date of Patent: November 26, 2013Assignee: Cool Polymers, Inc.Inventors: Kevin A. McCullough, James D. Miller
-
Publication number: 20130079972Abstract: Methods and maintenance systems for use in analyzing data related to maintenance of at least one vehicle are disclosed. One example method includes receiving at least one fault message, receiving a maintenance event log for a vehicle. The maintenance event log including at least one maintenance event associated with the at least one fault message. The example method further includes automatically identifying a corrective action within a most recent maintenance event of the at least one maintenance event and storing a diagnostic entry including the at least one fault message and the identified corrective action, such that the diagnostic entry is retrievable from the computing device to evaluate a subsequent like fault message.Type: ApplicationFiled: September 23, 2011Publication date: March 28, 2013Inventors: Peter James Lake, Davis Scott Kinney, Anne Kao, Stephen R. Poteet, Steven C. Runo, Jay Kevin McCullough, Steven D. Chapman, Yun-Ho Sikora, David Charles Augustine
-
Patent number: 8340948Abstract: A computer-based method for simulating an overall effect of a component replacement on the reliability of a platform is described. The method includes determining a scheduled reliability for a platform based on a reliability associated with each of the removable components of the platform, selecting, via a user interface, at least one removable component of the platform for which replacement is to be simulated, determining, using a computer-based model, an effect the one or more replacements would have on the forecasted reliability for the platform, and providing a comparison of the forecasted reliability and the scheduled reliability to a user.Type: GrantFiled: September 29, 2009Date of Patent: December 25, 2012Assignee: The Boeing CompanyInventors: Shuguang Song, Peter James Lake, Jay Kevin McCullough
-
Patent number: 8267149Abstract: A method of processing metal, metallic alloys, and metal matrix composites in a plastics injection molding machine is disclosed. The method includes the steps of providing a plastics injection molding machine having a screw. A step of removing the screw is included in the method. A step of replacing the screw with a modified screw configured and arranged for processing metals is also included. Alternatively, a step of removing the flights from the middle portion of the original screw shaft may be included.Type: GrantFiled: July 14, 2010Date of Patent: September 18, 2012Assignee: Cool Options, Inc.Inventor: Kevin A McCullough
-
Patent number: 8197730Abstract: A method is provided for forming a feedstock material for use in net shape molded component that includes an integral metallized coating or layer on the exterior surface thereof. The feedstock includes a carefully matched mixture of polymer resin and a metallic alloy that is suitable for use in a molding method that includes melting and injecting the material into a mold cavity under pressure. Due to the differential in material viscosities, the metal tends to migrate to the outer surface of the molded part when placed under pressure, ultimately creating a net shape molded part having a polymer core with a metallic layer at the exterior surfaces thereof.Type: GrantFiled: July 24, 2007Date of Patent: June 12, 2012Assignee: Cool Options, Inc.Inventor: Kevin A. McCullough
-
Patent number: 8147585Abstract: A metal alloy feedstock and method for metal injection molding is disclosed. The alloy includes at least two components, such as a first component and a second component. The first component has a first melting point and the second component has a second melting point higher than the first melting point. The first melting point and the second melting point match to the temperature gradient of the heated barrel of an injection molding machine whereby when fed into the injection molding machine the first component melts prior to the second component melts and enables the second component to solute into the first component. Additional components may also be used.Type: GrantFiled: September 17, 2009Date of Patent: April 3, 2012Assignee: Cool Polymers, Inc.Inventors: Kevin A. McCullough, James D. Miller
-
Publication number: 20110226439Abstract: A method of metal injection molding on an injection molding machine having a heated barrel with an increasing temperature gradient is disclosed. A first step includes providing a metal alloy feedstock including a first component having a first melting point and a second component having a second melting point that is higher than the first melting point, the first melting point and the second melting point selected to match the temperature gradient of the heated barrel of the injection molding machine. A second step includes feeding the metal alloy feedstock into the injection molding machine. A third step includes melting the metal alloy feedstock within the heated barrel of the injection molding machine. A fourth step includes maintaining the percentage of solids to liquids in the metal alloy feedstock of the first component and second component within a processable range of about 5% to about 30%.Type: ApplicationFiled: May 31, 2011Publication date: September 22, 2011Applicant: COOL POLYMERS, INC.Inventors: James D. Miller, Kevin A. McCullough
-
Publication number: 20100276104Abstract: A method of processing metal, metallic alloys, and metal matrix composites in a plastics injection molding machine is disclosed. The method includes the steps of providing a plastics injection molding machine having a screw. A step of removing the screw is included in the method. A step of replacing the screw with a modified screw configured and arranged for processing metals is also included. Alternatively, a step of removing the flights from the middle portion of the original screw shaft may be included.Type: ApplicationFiled: July 14, 2010Publication date: November 4, 2010Applicant: COOL OPTIONS, INC.Inventor: Kevin A. McCullough
-
Publication number: 20100068091Abstract: A metal alloy feedstock and method for metal injection molding is disclosed. The alloy includes at least two components, such as a first component and a second component. The first component has a first melting point and the second component has a second melting point higher than the first melting point. The first melting point and the second melting point match to the temperature gradient of the heated barrel of an injection molding machine whereby when fed into the injection molding machine the first component melts prior to the second component melts and enables the second component to solute into the first component. Additional components may also be used.Type: ApplicationFiled: September 17, 2009Publication date: March 18, 2010Applicant: COOL POLYMERS, INC.Inventors: James D. Miller, Kevin A. McCullough
-
Patent number: 7476702Abstract: A polymer composition having high thermal conductivity and dielectric strength is provided. The polymer composition comprises a base polymer matrix and a thermally-conductive, electrically-insulating material. A reinforcing material such as glass can be added to the composition. The polymer composition can be molded into packaging assemblies for electronic devices such as capacitors, transistors, and resistors.Type: GrantFiled: April 29, 2005Date of Patent: January 13, 2009Assignee: Cool Options, Inc.Inventors: E. Mikhail Sagal, Kevin A. McCullough, James D. Miller
-
Patent number: 7462309Abstract: A method for making a thermoplastic, thermally-conductive interface article is provided. The method used to make the interface article involves injection-molding a moldable composition into molding members. The moldable composition contains a base thermoplastic elastomer matrix, thermally-conductive filler material, and temperature-activated phase change material. The thermally-conductive articles can be used as thermal interfaces to dissipate heat from heat-generating electronic devices.Type: GrantFiled: December 16, 2004Date of Patent: December 9, 2008Assignee: Cool Shield, Inc.Inventors: James Miller, Kevin A. McCullough, E. Mikhail Sagal, Jeffrey Panek
-
Publication number: 20080217817Abstract: A screw and method for processing metal, metallic alloys, and metal matrix composites in a plastic injection molding machine is disclosed. The screw includes shank with a screw shaft extending from the shank. The screw shaft includes a rear portion proximate to the shank, a middle portion proximate the rear portion, and a front portion proximate the middle portion. Flights extend from the rear portion of the screw shaft for advancing material through the plastic injection molding machine into the middle portion of the screw shaft. Flights may optionally be included in the front portion of the screw.Type: ApplicationFiled: March 7, 2008Publication date: September 11, 2008Applicant: COOL OPTIONS, INC.Inventor: Kevin A. McCullough
-
Patent number: 7413691Abstract: A method is provided for forming a net shape molded component that includes an integral metallized coating or layer on the exterior surface thereof. The method includes injecting a carefully matched mixture of a molten polymer resin and a molten metallic alloy into a mold cavity under pressure. Due to the differential in material viscosities, the metal tends to migrate to the outer surface of the molded part when placed under pressure, ultimately creating a net shape molded part having a polymer core with a metallic layer at the exterior surfaces thereof. Further, the present invention provides for the compounding of a feedstock suitable for use in conjunction with the method described above.Type: GrantFiled: April 12, 2006Date of Patent: August 19, 2008Assignee: Cool Options, Inc.Inventor: Kevin A. McCullough
-
Patent number: 7311140Abstract: A net-shape molded heat sink is provided which includes a thermally conductive main body and a number of thermally conductive fins integrally connected to and emanating from the main body. The heat sink is formed by overmolding a carbon-carbon matrix core plate with a thermally conductive polymer composition that is filled with thermally conductive filler material. The molded heat sink is freely connecting through the part which makes it more efficient and has an optimal thermal configuration.Type: GrantFiled: November 5, 2002Date of Patent: December 25, 2007Assignee: Cool Options, Inc.Inventor: Kevin A. McCullough
-
Publication number: 20070264513Abstract: A method is provided for forming a feedstock material for use in net shape molded component that includes an integral metallized coating or layer on the exterior surface thereof. The feedstock includes a carefully matched mixture of polymer resin and a metallic alloy that is suitable for use in a molding method that includes melting and injecting the material into a mold cavity under pressure. Due to the differential in material viscosities, the metal tends to migrate to the outer surface of the molded part when placed under pressure, ultimately creating a net shape molded part having a polymer core with a metallic layer at the exterior surfaces thereof.Type: ApplicationFiled: July 24, 2007Publication date: November 15, 2007Applicant: COOL OPTIONS, INC.Inventor: Kevin McCullough
-
Patent number: 7236344Abstract: The apparatus for generating ionic flow of media includes a DC voltage supply having a positive terminal and a negative terminal with a collector connected to the negative terminal of the direct current voltage supply. The collector has a substantially tubular configuration with a rear and front section with inwardly tapering frusto-conical section therebetween. An emitter pin is connected to the positive terminal of the direct current voltage supply with the majority of the tip being located within the frusto-conical section of the collector. Alternatively, the front section of the collector may be made of a dielectric material, such as plastic. As a result, fluid flow, such as air flow, is generated from the input port of the rear section of the collector, through the frusto-conical section of the collector and out the output port of the front section of the collector.Type: GrantFiled: May 4, 2006Date of Patent: June 26, 2007Assignee: Cool Shield, Inc.Inventor: Kevin A. McCullough
-
Patent number: 7235918Abstract: A thermally-conductive polymer composition suitable for making molded reflector articles having light-reflecting surfaces is provided. The composition comprises: a) about 20% to about 80% by weight of a base polymer matrix such as polycarbonate; and b) about 20% to about 80% by weight of a thermally-conductive carbon material such as graphite. The composition can be used to make reflector articles such as housings for automotive tail lamps, head lamps, and other lighting fixtures. A method for manufacturing reflector articles is also provided.Type: GrantFiled: June 11, 2003Date of Patent: June 26, 2007Assignee: Cool Options, Inc.Inventors: Kevin McCullough, James Miller, E. Mikhail Sagal
-
Publication number: 20060250746Abstract: The apparatus for generating ionic flow of media includes a DC voltage supply having a positive terminal and a negative terminal with a collector connected to the negative terminal of the direct current voltage supply. The collector has a substantially tubular configuration with a rear and front section with inwardly tapering frusto-conical section therebetween. An emitter pin is connected to the positive terminal of the direct current voltage supply with the majority of the tip being located within the frusto-conical section of the collector. Alternatively, the front section of the collector may be made of a dielectric material, such as plastic. As a result, fluid flow, such as air flow, is generated from the input port of the rear section of the collector, through the frusto-conical section of the collector and out the output port of the front section of the collector.Type: ApplicationFiled: May 4, 2006Publication date: November 9, 2006Applicant: Cool Shield, Inc.Inventor: Kevin McCullough
-
Publication number: 20060243316Abstract: A thermal transfer device includes a body member having a base material of a first semiconductor material of a first type with a filler material dispersed therein of a second semiconductor material of a second type. Electrodes are attached on sides of the body member and electrical current is run therethrough to create thermal flow using the Peltier effect. The device is formed by injection molding and the like and the filler is introduced into the base by, for example, extrusion or pultrusion processes.Type: ApplicationFiled: April 26, 2006Publication date: November 2, 2006Applicant: Cool Shield, Inc.Inventor: Kevin McCullough