Patents Represented by Attorney, Agent or Law Firm Joseph W. Malleck
  • Patent number: 5872714
    Abstract: Method of rapidly producing a contoured part, comprising: designing a computer graphic model of the part, sectioning the graphic model into graphic members which are at least one of blocks or slabs, carving a solid member (14-150 mm in thickness) for each of the graphic members, the solid member being proportion to and enveloping such graphic members, the carving being carried out by accessing two or more sides (opposite sides) of such solid member to at least essentially duplicate the corresponding graphic member, and securing the carved solid members together to replicate the graphic model as a usable unitary part.The method can be modified to make castings by carving wax or foam solid members which are assembled to form an investment pattern, the was pattern being used in a shell mold casting steps and the foam pattern being used in evaporative casting steps.
    Type: Grant
    Filed: November 26, 1993
    Date of Patent: February 16, 1999
    Assignee: Ford Global Technologies, Inc.
    Inventors: Furqan Zafar Shaikh, Gregory Hugh Smith, Michael Raymond Rigley, Craig Edward Burch, Martin Andrew Brogley, Robert Francis Novak, Robert Walter Grenkowitz, Gerald A. Grab
  • Patent number: 5864777
    Abstract: A method of predicting volume of finished combustion chambers from a raw cylinder head casting including the steps of capturing cylinder head geometry of a raw cylinder head casting, transforming the captured cylinder head geometry into a machining coordinate system, virtual machining the raw cylinder head casting based on the transformed geometry, calculating a volume of combustion chambers of the virtually machined cylinder head, adding signed volumes of at least one component to the calculated volume to obtain a finished volume, and adjusting a mold for the raw cylinder head casting to achieve the desired finished volume.
    Type: Grant
    Filed: January 21, 1997
    Date of Patent: January 26, 1999
    Assignee: Ford Global Technologies, Inc.
    Inventors: Gregory Hugh Smith, Vijitha Senaka Kiridena, Samuel Edward Ebenstein, Yelena Mordechai Rodin
  • Patent number: 5863870
    Abstract: An iron or copper based metal powder useful for plasma deposition of a coating that has a dry coefficient of friction 0.75 or less and readily conducts heat through the coating. The powder comprises (a) H.sub.2 O atomized and annealed particles consisting essentially of (by weight) carbon 0.15-0.85%, oxygen 0.1-0.45%, an air hardening agent selected from manganese and nickel of 0.1-06.5%, and the remainder iron or copper, with at least 90% of the particles having oxygen and iron or copper combined in the lowest atomic oxygen form for an oxide of such metal.A method of making anti-friction iron powder that is economical, selectively produces FeO and promotes fine flowable particles. The method comprises (a) steam atomization of a molten steel that excludes other oxygen, the steel containing carbon up to 0.4% by weight to produce a collection of comminuted particles, and (b) annealing the particles in an air atmosphere for a period of time of 0.25-2.0 hours in a temperature range of 800.degree.-1400.degree. F.
    Type: Grant
    Filed: August 18, 1997
    Date of Patent: January 26, 1999
    Assignee: Ford Global Technologies, Inc.
    Inventors: V. Durga Nageswar Rao, Robert Alan Rose, David Alan Yeager, Carlo Alberto Fucinari
  • Patent number: 5853506
    Abstract: A method of treating metal working dies by the steps of: forming a metal working die part to be constituted of consolidated particulate material with a porosity in the range of 0.01-0.5%; immersing the part in a lubricant that is flowable under the working conditions of use for the die part, the lubricant being contained within a pressure chamber; raising the pressure within the chamber to 3,500 psi and the temperature of the lubricant to about 100.degree. C. for a period of time sufficient to allow the lubricant to migrate and be trapped within the micro pores of the part with a positive internal pressure; and placing into use the treated cold working die part so that such die part is subjected to shear, such use being without the need for burn in and redressing.
    Type: Grant
    Filed: July 7, 1997
    Date of Patent: December 29, 1998
    Assignee: Ford Motor Company
    Inventor: Fritz Meldrum
  • Patent number: 5850814
    Abstract: A cylinder block isolator core for use in casting engine cylinder blocks for internal combustion engines. The isolator core cooperates with companion core elements in a casting operation to form a short coolant jacket surrounding the upper portion of each engine cylinder adjacent the air/fuel combustion chamber and an air pocket that surrounds the lower region of the cylinder. Drainback passage core elements may be formed integrally with the isolator core thereby reducing the total number of cores in the casting mold package during a casting operation, the finished casting thereby eliminating dividing walls between the isolator and the oil drain cores thus reducing the number of core elements and reducing the cost and complexity of the casting operation as well as reducing the weight of the finished casting. The isolator core may be used independently of cylinder liners during the casting operation.
    Type: Grant
    Filed: April 7, 1998
    Date of Patent: December 22, 1998
    Assignee: Ford Global Technologies, Inc.
    Inventors: Gary Michael Fenn, Thomas John Heater, Mark Allen Hayley
  • Patent number: 5846289
    Abstract: A collection of agglomerated anti-friction grains for plasma deposition, the grains each consisting essentially of (a) H.sub.2 O atomized stainless steel particles, (b) solid lubricant particles consisting of at least one of boron nitride or a eutectic of calcium fluoride and lithium fluoride, and (c) a binder holding said steel and solid lubricant particles together for plasma spraying, said binder being present in an amount of 0.5-4.0% by weight and is vaporizable at the temperature of plasma spraying and does not interfere with the deposited process. A method of making agglomerated grains of powder suitable for plasma deposition, by (a) H.sub.
    Type: Grant
    Filed: July 9, 1996
    Date of Patent: December 8, 1998
    Assignee: Ford Global Technologies, Inc.
    Inventor: V. Durga Nageswar Rao
  • Patent number: 5846349
    Abstract: An iron or copper based metal powder useful for plasma deposition of a coating that has a dry coefficient of friction 0.75 or less and readily conducts heat through the coating. The powder comprises (a) H.sub.2 O atomized and annealed particles consisting essentially of (by weight) carbon 0.15-0.85%, oxygen 0.1-0.45%, an air hardening agent selected from manganese and nickel of 0.1-6.5%, and the remainder iron or copper, with at least 90% of the particles having oxygen and iron or copper combined in the lowest atomic oxygen form for an oxide of such metal.A method of making anti-friction iron powder that is economical, selectively produces FeO and promotes fine flowable particles. The method comprises (a) steam atomization of a molten steel that excludes other oxygen, the steel containing carbon up to 0.4% by weight to produce a collection of comminuted particles, and (b) annealing the particles in an air atmosphere for a period of time of 0.25-2.0 hours in a temperature range of 800.degree.-1400.degree. F.
    Type: Grant
    Filed: February 10, 1997
    Date of Patent: December 8, 1998
    Assignee: Ford Global Technologies, Inc.
    Inventors: V. Durga Nageswar Rao, Robert Alan Rose, David Alan Yeager, Carlo Alberto Fucinari
  • Patent number: 5845836
    Abstract: An aluminum clip useful for being bonded to glass and serving as a terminal for an electrical lead circuit in or on such glass, comprising: an aluminum-based body having a cup shape. The cup shape having a substantially flat surface; an ultra thin pad of noble metal adhered to the substantially flat surface, the pad presenting a surface roughness in the range of 1-5 microns.
    Type: Grant
    Filed: August 28, 1997
    Date of Patent: December 8, 1998
    Assignee: Ford Global Technologies, Inc.
    Inventors: Dawn Roberta White, Richard Lawrence Allor, John Scott Badgley, Jerald Edward Jones
  • Patent number: 5847958
    Abstract: Method of rapidly producing a contoured part, comprising: designing a computer graphic model of the part, sectioning the graphic model into graphic members which are at least one of blocks or slabs, carving a solid member (14-150 mm in thickness) for each of the graphic members, the solid member being proportion to and enveloping such graphic members, the carving being carried out by accessing two or more sides (opposite sides) of such solid member to at least essentially duplicate the corresponding graphic member, and securing the carved solid members together to replicate the graphic model as a usable unitary part.
    Type: Grant
    Filed: June 12, 1997
    Date of Patent: December 8, 1998
    Assignee: Ford Global Technologies, INc.
    Inventors: Furgan Zafar Shaikh, Martin Andrew Brogley, Craig Edward Burch, Gerry A. Grab, Robert Walter Grenkowitz, Robert Francis Novak, Michael Raymond Rigley
  • Patent number: 5842275
    Abstract: Method of surface mounting an electronic component to a bonding pad on one side of a supporting insulating board carrying a planar printed circuit thereon, the pad being connected to one or more conductors on the board by use of solder material subject to one or more gas trapping through-hole vias, comprising: (a) creating at least one vent channel below the top plane of the printed circuit and extending from a location at or closely adjacent to one of said vias to a location essentially near a periphery of solder material to be placed thereover; (b) planting a deposit of solder material between the component and pad; (c) bringing the component, solder material and pad together to form an assembly; and (d) heating the assembly to momentarily reflow the solder material in place without shifting, skewing, or tilting of the component, any trapped air in said one vias being allowed to expand and migrate away through the channel to at least the periphery of the pad.
    Type: Grant
    Filed: September 5, 1995
    Date of Patent: December 1, 1998
    Assignee: Ford Motor Company
    Inventors: Richard Keith McMillan, II, Vivek Amir Jairazbhoy, Robert Joseph Gordon, George Albert Garfinkel
  • Patent number: 5842109
    Abstract: A method for producing powder metal cylinder bore liners for an internal combustion engine includes the steps of loading a powder metal mixture into a die cavity of a die, compacting the powder metal mixture in the die cavity using uniaxial pressure from the die and forming the powder metal cylinder bore liner, and sintering the powder metal cylinder bore liner.
    Type: Grant
    Filed: July 11, 1996
    Date of Patent: November 24, 1998
    Assignee: Ford Global Technologies, Inc.
    Inventors: Edward Akpan, John E. Brevick
  • Patent number: 5820938
    Abstract: A method of fluxing a cast light-weight metal substrate for thermally adhering sprayed metallic coatings thereto, comprising: (a) preparing the substrate to be clean of grease and oil and to have a uniform and homogeneous surface energy; (b) electrostatically depositing a dry flux powder coating onto such prepared surface; and (c) thermally depositing melted metal onto and across the flux coated surface to further thermally activate the flux if not already activated, for stripping away any substrate oxides and to thermally metallurgically bond the deposited molten metal to the substrate.
    Type: Grant
    Filed: March 31, 1997
    Date of Patent: October 13, 1998
    Assignee: Ford Global Technologies, INc.
    Inventors: Deborah Rose Pank, Matthew John Zaluzec, Oludele Olusegun Popoola, Robert Edward DeJack, James R. Baughman, David James Cook
  • Patent number: 5820808
    Abstract: A method for forming an injection molded component from a host polymer (18) uses a very small quantity of an additive (32) that is efficiently driven to the surface of the component during the injection molding process. The additive exists in the host polymer at a very low concentration in the bulk, much lower than would be necessary to achieve the modification in a homogeneous blend. The additive is an insoluble liquid in the host polymer under the temperature and pressure conditions of injection molding. The additive is driven to the flow front surface (22) during injection molding and then translated to the surface (24) of the component by fountain flow and is distributed on the surface in a thin layer, producing the desired surface modification, without altering the properties of the bulk polymer, and eliminating post processing steps from the manufacturing process.
    Type: Grant
    Filed: January 16, 1997
    Date of Patent: October 13, 1998
    Assignee: Ford Global Technologies, Inc.
    Inventors: Henk van Oene, Deborah F. Mielewski, Kevin R. J. Ellwood
  • Patent number: 5821412
    Abstract: A diagnostic envelope is used to analyze measurements from an internal combustion engine. Measurements may be from a partially assembled engine during a cold test to detect subtle mechanical anomalies, or from a fully assembled engine during a cold test or a hot test (with active fuel and spark). The measurements represent vibrational amplitudes corresponding to various crankshaft angular positions of the internal combustion engine. The first step in generating the diagnostic envelope includes filtering the measurements to enhance local variations. Filtered measurements representing a number of engine cycles are then combined to reduce random cycle-to-cycle variations. The diagnostic envelope is then generated by subtracting corresponding measurements obtained from engines with known operating characteristics. The diagnostic envelope is used in analyzing and/or classifying the engine.
    Type: Grant
    Filed: August 9, 1994
    Date of Patent: October 13, 1998
    Assignee: Ford Global Technologies, Inc.
    Inventors: Bruce David Bryant, Kenneth Andrew Marko, Jimi Sauw-Yoeng Tjong, David Mansfield Mathias
  • Patent number: 5820939
    Abstract: A method of thermally spraying at least one adherent metallic coating onto an unroughened cleansed aluminum or aluminum alloy substrate to produce a coated substrate, comprising: wire-arc thermally spraying of melted metallic bonding droplets and fluxing particles onto the substrate using air propulsion to concurrently adherently deposit flux particles and bonding droplets, the spraying using air propulsion and a wire feedstock having a core and a sheath, the wire core being constituted of both metal powder readily metallurgically bondable to the substrate and a fluxing powder that readily deoxidizes the substrate, the wire sheath being constituted of pliable metal that is metallurgically compatible with the core metal powder, the fluxing powder having a halide salt chemistry effective to deoxidize the substrate upon contact of the melted fluxing powder therewith, said fluxing powder and bonding metal having a particle size that more uniformly promotes distribution throughout said spray.
    Type: Grant
    Filed: March 31, 1997
    Date of Patent: October 13, 1998
    Assignee: Ford Global Technologies, Inc.
    Inventors: Oludele Olusegun Popoola, Matthew John Zaluzec, Armando Mateo Joaquin, Deborah Rose Pank, David James Cook
  • Patent number: 5818006
    Abstract: An apparatus and method which utilize electrical discharge machining equipment and techniques to prepare an electrically conductive surface for thermal spray coating or for other purposes. The apparatus includes one or more electrodes, with each electrode having a working face, defining a plane. The one or more electrodes are mounted on the leading end of a shaft and can form part of an electrode assembly. The shaft is at least moveable axially by a shaft actuating mechanism and, in some applications, may also rotate the shaft. Each electrode is moveable by a gap setting mechanism in response to and in a direction different than the axial movement of the shaft to form a voltage gap between each working face and the surface being prepared. A supply of dielectric fluid is disposable in the voltage gap. An electrical discharge circuit conducts an electric current through the dielectric fluid in the gap to produce a gap voltage. The shaft actuating mechanism is controlled by a gap voltage control system.
    Type: Grant
    Filed: December 7, 1995
    Date of Patent: October 6, 1998
    Assignee: Ford Global Technologies, Inc.
    Inventors: Michael Joseph Habel, Larry Allen Peterson
  • Patent number: 5815789
    Abstract: A method for producing self lubricating powder metal cylinder bore liners for an internal combustion engine includes the steps of loading a powder metal mixture into a die cavity, compacting the powder metal mixture in the die cavity and forming the powder metal cylinder bore liner having a porous structure, sintering the powder metal cylinder bore liner, and impregnating the porous structure of the cylinder bore liner with lubricant.
    Type: Grant
    Filed: July 8, 1996
    Date of Patent: September 29, 1998
    Assignee: Ford Global Technologies, Inc.
    Inventor: Edward Akpan
  • Patent number: 5803156
    Abstract: A resin coated sand is blown into a core box to form an uncured core with a desired packing density. The core box has one or more inlets to permit ingress of gases and one or more outlets to permit egress of only gases. A non-catalyzing gas is passed through the defined sand core in the core box to create a first effluent and the hydrocarbon content in such first effluent that was exposed to the uncured resin of the sand core is measured. A catalyst carrying gas (nitrogen) is injected into the inlets to pass through the defined sand core within the core box for polymerizing the resin and thence exit from the outlets as a second effluent. The hydrocarbon content of the second effluent is continuously measured (i.e. non-dispersive infrared spectroscopy system). When the hydrocarbon content decreases to approximately the hydrocarbon content of the first effluent, the core box is opened to remove the sand core in a consistently cured condition.
    Type: Grant
    Filed: October 7, 1996
    Date of Patent: September 8, 1998
    Assignee: Ford Global Technologies, Inc.
    Inventors: Elaine Cecilia Beckwith, Thomas John Korniski, James Stewart Rankin, II
  • Patent number: 5801068
    Abstract: A microelectronic device is hermetically sealed at the wafer level. A substrate is provided having associated electronics and at least one metal bonding pad. A dielectric layer, such as pyrex glass film, is sputter deposited atop the substrate to form a glass/metal seal. A glass film is thereafter planarized, preferably by chemical-mechanical polishing, to remove surface variations. A cover wafer is thereafter anodically bonded to the dielectric layer/glass film so as to define a sealed cavity for housing and protecting the substrate electronics. The resultant microelectronic device is packaged in its own hermetically sealed container at the wafer level.
    Type: Grant
    Filed: November 7, 1996
    Date of Patent: September 1, 1998
    Assignee: Ford Global Technologies, Inc.
    Inventors: Kathirgamasundaram Sooriakumar, Allen Henry Meitzler, Shaun Leaf McCarthy, Russell J. Haeberle
  • Patent number: 5794484
    Abstract: Method of universally making waved parts by (a) providing a plurality of wave forming blocks each having a working surface in the form of a conical segment; (b) removably securing a plurality of such blocks to two arcuate supports (preferably discs) with the blocks spaced apart and with the axis of revolution of the block working surfaces aligned with the radius of the support to create a support-block assembly; and (c) facing and accurately bringing together such support-block assemblies with a deformable material (i.e., spring steel) therebetween, the blocks of one support being superimposed over the spaces between the blocks of the other support.
    Type: Grant
    Filed: November 23, 1993
    Date of Patent: August 18, 1998
    Assignee: Ford Global Technologies, Inc.
    Inventor: John Yas Jaddou