Patents Represented by Attorney, Agent or Law Firm Joseph W. Malleck
  • Patent number: 5958521
    Abstract: A method of thermally spraying a coating onto the interior of a cylindrical surface which coating is graded between enhanced optimal machinability and enhanced wear resistance.
    Type: Grant
    Filed: June 21, 1996
    Date of Patent: September 28, 1999
    Assignee: Ford Global Technologies, Inc.
    Inventors: Matthew J. Zaluzec, Armando M. Joaquin, Oludele O. Popoola
  • Patent number: 5947179
    Abstract: Method of sprayforming bulk metal deposits that replicate a master pattern: (i) casting and solidifying ceramic about a master pattern to form a spraying pattern; (ii) after removing the spraying pattern from the master pattern, heating the ceramic spraying pattern to a sustained temperature to effect an isothermal diffusion dependent microstructural transformation; (iii) while in such heated condition, thermally spraying allotropic metal particles onto the heated spraying pattern to form a deposit having a bulk thickness, the particles impacting the spraying pattern, or previously deposited particles, at a temperature above the sustained temperature of the spraying pattern; (iv) holding the deposit on the heated spraying pattern sufficiently long enough to allow the particles of the deposit to undergo a diffusion reaction that relieves internal stresses due to deposition and solidification; and (v) thereafter gradually cooling the deposit to room temperature to produce a unitary article with essentially no d
    Type: Grant
    Filed: July 30, 1998
    Date of Patent: September 7, 1999
    Assignee: Ford Motor Company
    Inventors: Jeffrey Alan Kinane, David Robert Collins, Grigoriy Grinberg, Paul Earl Pergande
  • Patent number: 5938948
    Abstract: Method of one side spot welding of a metallic auto body construction containing vaporizable coatings or ingredients, the construction having overlapping metal plys, comprising: impinging a plasma column on a selected spot of one side of the construction, the plasma column being generated by passing a plasma gas at a predetermined flow rate through an electrical arc created by a predetermined electrical current path; shielding the plasma column in an inert gas containing at least 5-35% by volume of oxygen, the shielded plasma column melting at least the metal on one ply at the spot while the oxygen increases the fluidity and wetablility of the melted metal and reduce its surface tension allowing any vaporization of the ingredients to quiescently escape through the molten metal; and ceasing plasma arc impingement for allowing the molten metal to solidify and complete the spot weld.
    Type: Grant
    Filed: July 21, 1997
    Date of Patent: August 17, 1999
    Assignee: Ford Global Technologies, Inc.
    Inventors: Alvin Kenneth Oros, Jay C. Chennat, Yoshihiro Yamaguchi
  • Patent number: 5938944
    Abstract: A plasma transferred wire arc thermal spray apparatus and method producing an extended-arc and supersonic plasma jet stream for applying a dense metallic coating on a substrate, such as a concave internal surface of a bore. The apparatus includes a plasma generating torch assembling having a cathode and an anode nozzle surrounding the cathode and a wire feeder which continuously feeds the tip of a wire feedstock opposite a constricted nozzle orifice and wherein the wire feedstock is maintained at the same positive electrical potential as the nozzle. Plasma gas is directed into the nozzle, preferably generating a vortex flow around the cathode and exiting the restricted nozzle orifice. The improved apparatus includes a pilot power supply and a high voltage or high frequency power supply which initiates the electric arc and the constricted plasma arc and a separate main power supply which extends the constricted plasma arc to the wire tip.
    Type: Grant
    Filed: April 9, 1998
    Date of Patent: August 17, 1999
    Assignee: Ford Global Technologies, Inc.
    Inventors: James Richard Baughman, David James Cook, Daniel R. Marantz, Keith A. Kowalsky
  • Patent number: 5934236
    Abstract: A low friction valve train actuating at least one valve in an internal combustion engine includes a cam shaft having at least one cam, a tappet contacting the cam and valve, the cam and valve having outer surfaces with an open porosity, a solid film lubricant impregnated and anchored in the open porosity, the solid film lubricant is stable to temperatures at about 700.degree. F. to retain a low coefficient of friction in an oil starved environment.
    Type: Grant
    Filed: January 19, 1994
    Date of Patent: August 10, 1999
    Assignee: Ford Global Technologies, Inc.
    Inventors: V. Durga Nageswar Rao, Daniel Michael Kabat, Harry Arthur Cikanek
  • Patent number: 5925298
    Abstract: A method and apparatus for forming a rigid circuit board has a circuit board with a reduced thickness in a bend region. The bend region may have several layers of laminate and conductive material. The circuit board is heated to the glass transition temperature which allows the circuit board to become flexible. The apparatus has a clamping member and a stationary member. The clamping member uses a shape memory alloy actuator with a transition temperature about the same as the glass transition temperature of the laminate. The actuator is used to form the bend region to a predetermined shape around the stationary member. When the circuit board is cooled, the circuit board again becomes rigid in its predetermined shape.
    Type: Grant
    Filed: June 26, 1995
    Date of Patent: July 20, 1999
    Assignee: Ford Motor Company
    Inventors: Bethany Joy Walles, Michael George Todd, Robert Edward Belke, Jr.
  • Patent number: 5924475
    Abstract: A method of making sand cores to obtain optimum mechanical properties and particularly to obtain accurate adjustment of the gas curing cycle for making optimum resin-coated sand cores.
    Type: Grant
    Filed: May 5, 1997
    Date of Patent: July 20, 1999
    Assignee: Ford Global Technologies, Inc.
    Inventors: Elaine Cecilia Beckwith, James Stewart Rankin, II, Warren Benjamin Copple
  • Patent number: 5922412
    Abstract: A method of eliminating unevenness in pass-reversal thermal spraying of a substrate surface by: uniformly thermally spraying a substrate surface by moving a wire fed arc spray gun along the length of the substrate surface at constant spray parameters while using a first wire feed rate and a first current level for the gun's power supply; (b) when said spray gun approaches an end zone of the pass length requiring reversal of spray gun movement, reducing the wire feed rate and current by up to about 25% until the spray gun has completed such reversal and has exited from said end zone in the opposite direction; (c) while still continuing thermal spraying, restoring the wire feed rage and current to said first levels; and (d) repeating steps (b) and (c) as the spray gun approaches other or repeated end zones of the substrate length during repeated passes.
    Type: Grant
    Filed: March 26, 1998
    Date of Patent: July 13, 1999
    Assignee: Ford Global Technologies, Inc.
    Inventors: James Richard Baughman, David James Cook
  • Patent number: 5921460
    Abstract: A method of soldering materials by controlling ultrasonic energy to effect melting of only the solder in an assembly to be joined that is carried on a low temperature melting substrate.
    Type: Grant
    Filed: June 5, 1997
    Date of Patent: July 13, 1999
    Assignee: Ford Motor Company
    Inventors: Mark Stephen Topping, Cuong Van Pham, Brian John Hayden
  • Patent number: 5920383
    Abstract: A strain gauge includes an image sensing device having a lens, a magnification lens optically coupled to the lens, a positioning mechanism connected to the image sensing device, an image capture device for receiving an image from the image sensing device, and a processor for mathematically analyzing the image received from the image capture device and to calculate strain.
    Type: Grant
    Filed: December 5, 1997
    Date of Patent: July 6, 1999
    Assignee: Ford Global Technologies, Inc.
    Inventors: Fang Chen, Anthony M. Waas, Everett You-Ming Kuo, Howard Kiel Plummer, Jr., Thomas Eugene Allen
  • Patent number: 5913353
    Abstract: A process for casting light metals. The process includes preheating ingots of the light metal in a protective atmosphere before being introduced into a melting furnace wherein the molten metal is degassed and filtered before transference in a heated delivery tube to a covered holding furnace. The filtered melt is made quiescent to reduce its kinetic energy and allow inclusions to settle and form a purified melt. A vacuum is applied to a die cavity in a casting press to displace air residing therein with an inert atmosphere. The purified melt is then transferred in a heated delivery tube as a charge to the casting press under the inert atmosphere to prevent burning and formation of accompanying reaction products. Upon cooling, a light metal casting is produced in the absence of air with minimum defects and inclusions.
    Type: Grant
    Filed: March 24, 1998
    Date of Patent: June 22, 1999
    Assignee: Ford Global Technologies, Inc.
    Inventors: James Edward Riley, Curtis Neal Paige
  • Patent number: 5914534
    Abstract: A three-dimensional multi-layer molded electronic device and method for manufacturing same, wherein the device comprises at least two molded, three-dimensional substrates having mating surfaces, each substrate including a layer of patterned conductive material on at least one surface and electrically conductive vias at selected locations of the substrate for interconnection of the conductive layers, wherein the substrates are electrically joined at their mating surfaces and the circuit layers are aligned and interconnected to form a multi-layer, three-dimensional circuit which may include molded-in structural features.
    Type: Grant
    Filed: May 3, 1996
    Date of Patent: June 22, 1999
    Assignee: Ford Motor Company
    Inventors: Michael George Todd, Peter Joseph Sinkunas, Andrew Zachary Glovatsky
  • Patent number: 5909839
    Abstract: A method is provided for applying a fluid to a plurality of locations on a non-planar substrate. The apparatus used includes a movable base and an array of pins connected to the base. Each pin has a distal end which is vertically movable with respect to the base independently of the rest of the array of pins. Each distal end is adapted to transfer fluid to a location on the substrate by having a greater affinity for the fluid than the fluid has for itself and a lesser affinity for the fluid than the fluid has for the substrate. Accordingly, the distal ends may be dipped in the fluid and moved into contact with the substrate such that the distal ends may collapse toward the base as the distal ends engage the substrate to facilitate further movement of the base toward the substrate for application of fluid to each of the plurality of locations.
    Type: Grant
    Filed: May 15, 1997
    Date of Patent: June 8, 1999
    Assignee: Ford Motor Company
    Inventors: Robert Edward Belke, Jr., John Trublowski, Michael George Todd
  • Patent number: 5903458
    Abstract: An improved Direct Surface Manipulation (DSM) method is disclosed which incorporates a global surface reparametrization scheme for the purposes of extending the DSM method to applications involving multiple surfaces and for reducing the geometric effect of parametric space distortions on the features. This method reparametrizes multiple surface patches with a shared two-dimensional space defined in the object space of the model. The result is a geometrically consistent mesh, called a super-mesh, that serves as a global, uniform parametric space for topologically-disconnected, geometrically-disproportional surface patches. Spherical projection is employed to perform the patch reparametrization. This allows the creation of DSM features on multiple surface patches with improved shape quality.
    Type: Grant
    Filed: June 6, 1997
    Date of Patent: May 11, 1999
    Assignee: Ford Global Technologies, Inc.
    Inventors: Paul Joseph Stewart, Yifan Chen
  • Patent number: 5900282
    Abstract: A method of depositing a dielectric coating, comprising the steps of forming an unroughened or roughened, as-cast or wrought substrate surface to receive the coatings; and flame spraying a single premixed thermoplastic epoxy/hardener powder onto the surface, the resultant in-flight heated powder being chemically activated to impact the surface and form a chemically adhering coating, the coating being cured in-situ to be dielectric and thermally conductive.
    Type: Grant
    Filed: January 20, 1998
    Date of Patent: May 4, 1999
    Assignee: Ford Global Tech nologies, Inc.
    Inventors: David Robert Collins, Paul Earl Pergande, Matthew John Zaluzec, Armando Mateo Joaquin, Jeffrey Alan Kinane
  • Patent number: 5897964
    Abstract: An automotive body glass product, comprising: (a) a laminated glass having its perimeter painted to obscure the presence of applied adhesives; (b) conductive leads on or in the glass and having one or more conductive lead terminals; (c) an ultra thin pad of noble metal deposited onto a small zone of the glass in connection with at least one terminal; and (d) a conductive metal clip connected to the end of each lead path, said clip having a dimple thereof bonded to the pad by inertial welding of the dimple and noble metal pad material.
    Type: Grant
    Filed: August 28, 1997
    Date of Patent: April 27, 1999
    Assignee: Ford Global Technologies, Inc.
    Inventors: Dawn Roberta White, Richard Lawrence Allor, John Scott Badgley, Jerald Edward Jones
  • Patent number: 5887646
    Abstract: A portable sand mold metal treating system having sand cope and sand drag portions, the treating system being attachable to a sand mold metal casting system.
    Type: Grant
    Filed: January 16, 1997
    Date of Patent: March 30, 1999
    Assignee: Ford Global Technologies, Inc.
    Inventors: Walter Evans, Leslie Terner, Frank Tibaudo
  • Patent number: 5885091
    Abstract: A method and apparatus is provided for electrically interconnecting a circuit pattern with an adjacent circuit on a substrate. The circuit pattern is positioned in direct physical contact with the adjacent circuit to create a single electrical interface between the circuit pattern and the adjacent circuit. A compliant spring member is supported by the substrate for creating a normal force at the single electrical interface for holding the circuit pattern and adjacent circuit together. The compliant spring member is sufficiently flexible to facilitate electrical interconnection of the circuits along a non-planar substrate. Various embodiments are described.
    Type: Grant
    Filed: May 5, 1997
    Date of Patent: March 23, 1999
    Assignee: Ford Motor Company
    Inventors: Thomas Dudley Belanger, Jr., John Trublowski, Joseph Valentine Bejster, Douglas Hughson, Jr.
  • Patent number: 5876155
    Abstract: A method that eliminates or reduces chatter when plunge cutting with boring cutters at different diameters, different tool geometries, different chip loads and different cutting depths, by computing optimal cutting insert locations and relocating such inserts to such optimal cutting locations with different phase angles therebetween; this minimizes the resultant radial force of the combined cutters.
    Type: Grant
    Filed: May 15, 1997
    Date of Patent: March 2, 1999
    Assignee: Ford Global Technologies, Inc.
    Inventors: Gregory Link, Yefim Val, Jide Jin, Mariano Martin, Juhchin Yang
  • Patent number: 5872322
    Abstract: A method of making a structural iron-based article comprising: (a) blending a compressible base iron powder (max. particle size of 100 microns) a graphite powder to provide carbon in mixture, and a single master alloy powder (average particle size of 10 microns) meltable within the range of 900.degree.-1200.degree. C. (1690.degree.-2220 .degree.F.) to form a mixture, the master alloy powder being present in an amount of 1-5% by weight of the mixture and consisting of (i) hardenability enhancing alloying ingredients selected from Mn, Mo, Ni, Cr, Cu and Fe, with Fe being present only if Cr or Mo is selected and (ii) wetting agents selected from the group of B, Y, Si and rare earth misch metal, the master alloy being devoid of carbon and being proportioned to provide a desired amount of hardenability in the base powder; (b) compacting the mixture to a green density 7.1-7.4 g/cm.sup.
    Type: Grant
    Filed: February 3, 1997
    Date of Patent: February 16, 1999
    Assignee: Ford Global Technologies, Inc.
    Inventors: Stanislaw Mocarski, Charles Oliver Mchugh, Russell A. Chernenkoff, David Alan Yeager