Patents Represented by Attorney, Agent or Law Firm Joseph W. Malleck
  • Patent number: 6060117
    Abstract: Method of making a mask assembly by providing a heat resistance mask substrate having an exposed surface with a surface smoothness less than 2000 micro inches, uniformly spraying a thermoset epoxy organic coating onto such exposed surface in one or more layers to provide a coating having (e.g., a thickness equal to or less than about 0.005 inches), a smoothness characterized by an average profilometer reading (Ra) of no greater than 1.5 micrometers, said coating being devoid of pores that exceed about 0003 inch in size, and flame polishing all or a portion of such coating to effect a surface finish of about 1.0 micrometers. A mask assembly which is useful in masking areas from thermal spray particles, comprising a heat resistance substrate presenting an exposed grit blasted surface having a smoothness of less than 2000, and a thin thermoset epoxy coating bonded to said exposed surface and having a surface smoothness characterized by an average profilometer reading (Ra) no greater than 1.5.
    Type: Grant
    Filed: August 31, 1998
    Date of Patent: May 9, 2000
    Assignee: Ford Global Technologies, Inc.
    Inventors: Paul Earl Pergande, Jeffrey Alan Kinane, Deborah Rose Pank, David Robert Collins
  • Patent number: 6056189
    Abstract: A flux formulation without a surfactant is available for use in the assembly of electronic circuit boards as a no-clean formulation. The formulation includes a flux solution having a fluxing agent consisting essentially of one or more weak organic acids and a solvent consisting essentially of water. The flux solution serves to transport the fluxing agent before deposition thereof upon a soldering site for reliability improvement engendered by a lack of hygroscopic residue and for avoidance of environmental degradation engendered by a lack of volatile organic chemicals (VOC's). The method includes the steps of heating the flux solution and dispersing it as a fine spray.
    Type: Grant
    Filed: March 13, 1998
    Date of Patent: May 2, 2000
    Assignee: Ford Global Technologies, Inc.
    Inventors: Guilian Gao, Lakhi Nandlal Goenka
  • Patent number: 6050560
    Abstract: Clamping apparatus for holding a motor vehicle window pane wherein a window pane (6) is fixed to and moved in a height-adjustable manner on a driver holder (2) of a window lifting mechanism (1), said clamping means comprising a driver holder (2) having at least one concave surface and a clamping plate (3) which can be braced against the window pane (6) by means of a fastening element (7), with the interposition of spacers (4 and 5), the driver holder (2) and the clamping plate (3) each have a pair of upper and lower recesses (11 and 12 respectively) concave to the window pane (6) and the clamping plate (3) is held parallel to these by prismatic guide means (8/9) on the driver holder (2), the window pane (6) is embraced by directly interposed spacers (4 and 5) having on their outer faces convex upper and lower raised portions (13 and 14 respectively) corresponding to the respective concave recesses (11 and 12), and the window pane, held in a desired installed position by a device, can be clamped fast in the de
    Type: Grant
    Filed: March 16, 1999
    Date of Patent: April 18, 2000
    Assignee: Ford Global Technologies, Inc.
    Inventor: Bruno Schuetteler
  • Patent number: 6050881
    Abstract: Method of surface finishing covalent-ionic ceramics comprising: (a) repeatedly rubbing a finishing medium against an exposed surface of the ceramic, the medium being constituted of an ionic bonded oxide having grains harder than the grains of the covalent-ionic bonded ceramic; (b) interrupting the rubbing at frequent intervals to dress the medium by a single point diamond tool; and (c) continuing the repeated rubbing and dressing interruptions of steps (a) and (b) until a surface roughness of about 0.04 micrometer Ra has been achieved on the ceramic and the exposed surface of the ceramic retains an ionic residue of the finishing medium. Also, a method of effecting reduced friction between lubricated rubbing surfaces, comprising: (a) forming one of the rubbing surfaces of silicon nitride based ceramics having a polished surface roughness about 0.
    Type: Grant
    Filed: July 27, 1998
    Date of Patent: April 18, 2000
    Assignee: Ford Global Technologies, Inc.
    Inventors: Richard Lawrence Allor, Gary Mark Crosbie, Douglas George Mcwatt, Arup Kumar Gangopadhyay
  • Patent number: 6026569
    Abstract: A heat exchanger and method of assembly for an automotive vehicle includes at least one tube having an internal surface and an external surface, and a composition cladding having at least magnesium applied to the internal surface and external surface of the tube.
    Type: Grant
    Filed: February 24, 1998
    Date of Patent: February 22, 2000
    Assignee: Ford Motor Company
    Inventors: Tim V. Evans, Matthew J. Zaluzec, Gerry A. Grab, Henry Mehraban, Jeffrey S. Southwood
  • Patent number: 6021660
    Abstract: A flexible tooling fixture that has a pallet bed lying within an x-y plane and reference elements for alignment of the bed to the manufacturing tool; and at least two sets of supports extending from the top of the pallet bed, each set consisting of: (i) a flexible pivot to accurately locate differing brackets of the sensor assemblies to maintain the axis of the barrel in a common z-x plane, the z-x plane being off-set from the center of the bed, and (ii) one or more fixed stops for engaging the barrel and bracket of each assembly to determine a common-x-y position for each sensor module with the axis of the barrel in a predetermined relation to the bed, one set of supports being located to determine alignment of the axes of one class of sensor assemblies within the predetermined position, and the other set being located to determine alignment of the axes of another class of sensor assemblies within the same predetermined z-x plane when the bed is in a second position that is 180.degree.
    Type: Grant
    Filed: September 15, 1997
    Date of Patent: February 8, 2000
    Assignee: Ford Motor Company
    Inventors: Christopher Winthrup Pike, Thomas Richard Trafford
  • Patent number: 6017591
    Abstract: A method of defining valve seats on valve seat supports of an internal combustion engine head. The method includes steps of; (a) roughening the exposed surface of the valve seat support to a finish of 10-50 .mu.m RA; (b) thermally spraying a stream of composite particles onto the roughened support surface, using gaseous propellants with sufficient heat and force to produce a dense adherent composite coating of metal and metal oxide particles and to a thickness no greater than 1-1.5 mm; and (c) finish machining if necessary, the sprayed coating to define the valve seat surface. The composite coated product consists of a metal/metal oxide mixture that possesses one or more of the following characteristics: a surface porosity of 2-5%, a density of 6.5-8 grams/cc, a Vickers hardness of about 280 kg/mm.sup.2 at 450.degree. C., high wear resistance and high corrosion resistance.
    Type: Grant
    Filed: November 14, 1996
    Date of Patent: January 25, 2000
    Assignee: Ford Global Technologies, Inc.
    Inventors: Oludele Olusegun Popoola, Robert Corbly McCune, Larry Van Reatherford, Eddie Lee Cartwright
  • Patent number: 6014876
    Abstract: A tamper-proof locking mechanism for a vehicular engine compartment, the compartment having a (a) hood closure member with a striker secured within the compartment to the hood; (b) a latch mechanism having a movable latch for catching and holding the striker when such striker is brought into a predetermined position relative to compartment; (c) a bracket secured or connected to the other closure member having (i) walls secured to the latch mechanism for fixing such mechanism in a desired spatial position for receiving the striker, (ii) a saddle with spaced walls defining a track closed at one end by the saddle; and (d) a lock having a housing provided with (i) a tumbler body slidable in and along the track and nestable on the saddle for being secured in an operative position, (ii) housing flanges at opposite regions of the body that overlap the edges of both of the spaced saddle walls, each flange contacting the edges of the side walls at one end of the body to ride thereon and fit flush thereagainst as well
    Type: Grant
    Filed: January 4, 1999
    Date of Patent: January 18, 2000
    Assignee: Ford Global Technologies, Inc.
    Inventor: Steven Michael Taylor
  • Patent number: 6011313
    Abstract: A device which utilizes flip chip technology to provide interconnection between printed circuit boards and integrated circuits is disclosed. The method involves metallization of the bond pad and multiple, novel bump compositions and coating compositions to provide an interconnection which is reliable and which withstands differences in the coefficient of thermal expansion between the silicon device and the bump material.
    Type: Grant
    Filed: February 1, 1999
    Date of Patent: January 4, 2000
    Assignee: Ford Motor Company
    Inventors: Dongkai Shangguan, Mohan Paruchuri, Achyuta Achari
  • Patent number: 6009378
    Abstract: A method is disclosed for developing a sheet metal forming process prediction method which is based on the application of an anisotropic hardening rule of plasticity in the mathematic theory.
    Type: Grant
    Filed: October 14, 1997
    Date of Patent: December 28, 1999
    Assignee: Ford Global Technologies, Inc.
    Inventors: Sing Chih Tang, James Calvey Carnes
  • Patent number: 6000597
    Abstract: An apparatus for dispensing solder includes a nozzle body having a plurality of flow channels formed therein. Each flow channel includes an inlet end and a dispenser end for dispensing solder. The nozzle body forms a nipple surrounding each dispenser end, and the nozzle body further forms a shielding chamber in communication with each dispenser end for protecting the respective nipple, and optionally providing flow of inerting gas and/or excluding ambient oxygen from the soldering area. The nozzle bodies comprise micro-machined silicon. Various flow channel configurations are provided for improved flow characteristics.
    Type: Grant
    Filed: January 28, 1998
    Date of Patent: December 14, 1999
    Assignee: Ford Motor Company
    Inventors: Marc Alan Straub, Frank Burke DiPiazza, Vivek Amir Jairazbhoy, Lakhi Nandial Goenka, Randy Claude Stevenson
  • Patent number: 6000747
    Abstract: A door assembly for a vehicle includes a door subassembly hinged to the vehicle having a window opening and a window subassembly hinged to the vehicle adapted to cover the window opening; the door subassembly and window subassembly having a common hinge axis and the door assembly operable between a closed position, a window subassembly open and door subassembly closed position, and a window subassembly and door subassembly open position.
    Type: Grant
    Filed: August 10, 1998
    Date of Patent: December 14, 1999
    Assignee: Ford Global Technologies, Inc.
    Inventors: Rakesh Sehgal, Phillip Joseph Linson, David William Hinze, Clarke Michael Cunningham
  • Patent number: 5992583
    Abstract: Method of stabilizing valve lift-off movement in an automotive hydraulic shock absorber having compression and expansion chambers filled with a hydraulic shock-absorber fluid is diclosed. The chamber are divided by a valve body which has one or more orifices that have fluid flow therethrough controlled by a spring biased valve that lifts off from the valve body when the fluid pressure differential between chambers is above a predetermined amount.
    Type: Grant
    Filed: March 27, 1998
    Date of Patent: November 30, 1999
    Assignee: Ford Global Technologies, Inc.
    Inventors: Benjamin J Saltsman, Colin Jeffrey Young, Michael James Lynch, William M. Stewart
  • Patent number: 5983495
    Abstract: Method of making seat inserts by thermally spraying bulk material. The method includes the steps of: (i) preparing a mandrel having an outside dimension not greater than the desired inside dimension of the desired insert, the mandrel having a part to provide for separation of the sprayed bulk material from the mandrel, (ii) thermal spraying separate particles of one or more types of steel or nickel alloys in the presence of a controlled oxidizing medium to form a bulk composite material on the mandrel with a density of at least 99% and, (iii) after cooling the bulk material, removing such material from the mandrel and slicing it into discrete seat shapes for implanting into the final product.
    Type: Grant
    Filed: December 29, 1997
    Date of Patent: November 16, 1999
    Assignee: Ford Global Technologies, Inc.
    Inventors: Oludele Olusegun Popoola, Larry Van Reatherford, Robert Corbly McCune, Armando Mateo Joaquin, Eddie Lee Cartwright
  • Patent number: 5976704
    Abstract: A composite metallizing wire useful in thermal flame spraying, having a conductive metallic solid core wire strand and a coating consisting of solid lubricant particles (i.e., graphite, BN, Teflon) and wear-resistant particles (i.e., SiC, TiC, Cr.sub.3 C.sub.2) homogeneously suspended in a conductive metal (i.e., Ni, Fe, Cr, Mo, Ti) complementary to said solid core wire strand.A method of making such composite metallizing wire useful in thermal flame spraying, comprising submersing a solid core wire mandrel of conductive metal in a plating bath to act as a cathode, the bath containing conductive metal salt and an electrolyte having a salt with a depositable metal and a dispersant of wear-resistant particles (i.e., in an amount of from 20-150 grams/liter) and solid lubricant particles (i.e., in an amount of from 10-200 grams/liter), and energizing the electrolyte to codeposit metal from said electrolyte along with wear-resistant particles and solid lubricant particles onto said wire mandrel.
    Type: Grant
    Filed: August 14, 1995
    Date of Patent: November 2, 1999
    Assignee: Ford Global Technologies, Inc.
    Inventor: Robert Corbly McCune
  • Patent number: 5967660
    Abstract: A method and apparatus of providing accelerated thermal fatigue testing of an engine component, comprising: (i) impinging one or more torch flames directly on a selected area of the test specimen (i.e. metallic engine cylinder head) to heat such area to a critical test temperature that exceeds the normal maximum loading temperature of the specimen in normal use by about 10-25%, and holding such temperature for a period of 0.01-2.0 minutes; (ii) at the end of the holding period (ie. Water jet water in head jacket, or air in ports) quenching the heated area of the test specimen to a temperature that is about 75% below that of the normal maximum loading temperature and holding such quenching temperature for about 1-3 minutes; and (iii) repeating steps (i) and (ii) until a crack is induced in the test specimen while recording the history of temperature and time involved in such repeated steps.
    Type: Grant
    Filed: December 22, 1997
    Date of Patent: October 19, 1999
    Assignee: Ford Global Technologies, Inc.
    Inventors: Edward Akpan, Jeff Lee Branson, Blake Ross, John Loncke, Long T. Dinh, Richard Piekos
  • Patent number: 5964022
    Abstract: Method of mounting a brake rotor to a wheel hub, the mounting establishing a sealed but removable fixed bearing therebetween; it comprises the steps of: (a) forming mating metallic mounting surfaces on the respective rotor and hub that at least in part extend in a plane normal to the axis of rotation of the hub (for example, within a tolerance .+-.0.
    Type: Grant
    Filed: December 29, 1997
    Date of Patent: October 12, 1999
    Assignee: Ford Global Technologies, Inc.
    Inventors: David Maurice Mann, George Abram Thornton
  • Patent number: 5961853
    Abstract: Method of resistance brazing of light metal alloys to form a corrosion resistant structural assembly, comprising: positioning a patch (thickness of about 0.05-0.25 mm and an aspect ratio of about one) of brazing filler metal between and in contact with superimposed light metal (i.e., aluminum, titanium) alloy structural workpieces to define a joining spot, said filler metal consisting of 7-13% silicon, substantial absence of magnesium and copper for aluminum workpieces, and the balance said light metal; while applying high pressure to force the workpieces together at the joining spot to achieve a structural joint, resistively heating the patch to melting without softening the workpieces, except at interfaces with the filler metal, by flowing an electrical current through the patch and aligned portions of the workpieces under ambient conditions and in the absence of flux, the heating and pressure being sufficient to mechanically break up and eliminate any oxides in the workpieces at the joining spot.
    Type: Grant
    Filed: April 24, 1995
    Date of Patent: October 5, 1999
    Assignee: Ford Global Technologies, Inc.
    Inventor: Peter Howard Thornton
  • Patent number: 5958262
    Abstract: A spot welding apparatus having a welding gun with movable and fixed electrodes carried on an articulating wrist, the apparatus comprising: a) a robotically actuated articulating wrist carrying the gun for movement to and from a welding position for a workpiece; b) a primary cylinder assembly connecting the wrist to the movable electrode of the gun for imposing pressure by such movable electrode to the workpiece and to the fixed electrode during a welding stroke toward the workpiece; and c) a fixing cylinder assembly connecting the wrist to the fixed electrode, the fixing cylinder assembly having (i) a fixing cylinder housing with a movable fixing piston therein connected to the fixed electrode of the welding gun and having a fixing piston stop, (ii) a primary balancing spring acting between the fixing cylinder housing and the movable fixing piston to carry the weight of the gun, (iii) structure for introducing a fixing air pressure into the fixing cylinder housing to urge the fixing piston to a position lock
    Type: Grant
    Filed: January 19, 1999
    Date of Patent: September 28, 1999
    Assignee: Ford Global Technologies, Inc.
    Inventors: Michael Palko, James Wayne Dolfi, Keith Albert Dils
  • Patent number: 5958151
    Abstract: A flux formulation without a surfactant is used in the assembly of electronic circuit boards as a no-clean formulation. The formulation includes a flux solution having a fluxing agent consisting essentially of one or more weak organic acids and a solvent consisting essentially of water. The flux solution serves to transport the fluxing agent before deposition thereof upon a soldering site for reliability improvement engendered by a lack of hygroscopic residue and for avoidance of environmental degradation engendered by a lack of volatile organic chemicals (VOC's). The method comprises the step of heating the flux solution and dispersing it as a fine spray.
    Type: Grant
    Filed: July 22, 1996
    Date of Patent: September 28, 1999
    Assignee: Ford Global Technologies, Inc.
    Inventors: Guilian Gao, Lakhi Nandlal Goenka