Patents by Inventor Allen Dennis Roche
Allen Dennis Roche 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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Publication number: 20090023013Abstract: According to one embodiment, a composite mold for use in molding a part having a textured surface is disclosed. The composite mold includes a mold base that forms the base of the composite mold. The mold base includes a mold base surface. The composite mold also includes a spray formed thin layer including a first surface having one or more fine features and a second surface opposing the first surface. The second surface is coupled to the mold base to form the composite mold having the first surface as the molding surface. The composite mold is capable of forming a molded part having a textured surface including surface features representing a reciprocal facsimile of the one or more fine features on the molding surface.Type: ApplicationFiled: July 17, 2007Publication date: January 22, 2009Applicant: FORD MOTOR COMPANYInventors: Allen Dennis Roche, David Robert Collins
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Patent number: 6955209Abstract: A method and arrangement for implementing post-heat treatment after spray forming is ended to achieve stress control in the manufacture of a spray formed metallic tool involves providing a spray-formed metallic tool by applying a spray-forming material on a mold substrate and causing substantially homogenous metallic phase transformations of the spray forming material within the spray-formed metallic tool to a substantially homogenous distribution of commingled metallic phases consisting, for example, of predetermined proportions of at least a bainite phase and a martinsite phase.Type: GrantFiled: November 27, 2001Date of Patent: October 18, 2005Assignee: Ford Motor CompanyInventors: Richard L Allor, Allen Dennis Roche, Samir Samir
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Patent number: 6949299Abstract: The present invention relates to a method of spray forming a boron steel metal article, and to the formed article. In at least one embodiment, the method comprises (a) providing a spray forming pattern, (b) spraying metallic particles onto the spray forming pattern, and (c) allowing the sprayed metallic particles to cool to form a metal article. In at least one embodiment, the metallic particles are sprayed from a carbon steel feedstock having a boron content of 0.25-2.25 weight percent, based on the total weight of the feedstock.Type: GrantFiled: June 25, 2004Date of Patent: September 27, 2005Assignee: Ford Motor CompanyInventors: Allen Dennis Roche, David Robert Collins, Richard L. Allor
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Patent number: 6923241Abstract: Method and apparatus for controlling stresses in a spray form process makes use of one dimensional modeling in which characteristics of a geometrical point are quantified by iterative detection, such as taking a surface temperature reading using a pyrometer. This temperature information is used in a one dimensional simulation to predict characteristics for a column from the point down through a spray-formed article to an interface with a substrate. The modeling technique can used with a plurality of geometrical points to model the whole article, and the one dimensional simulation can be integrated with robotic spray-forming controls to minimize residual stress in the spray-formed article.Type: GrantFiled: November 27, 2001Date of Patent: August 2, 2005Assignee: Ford Motor CompanyInventors: Allen Dennis Roche, Samir Samir, Chijoke Mgbokwere, Mark Lusk
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Patent number: 6904950Abstract: Method and apparatus for controlling a spray-forming process incorporating time, temperature, and transformation dependent stress relief techniques involves the manipulation of both temperature and time for strategic phase changes that result in a specific and planned volumetric increase. This manipulation is made based on controlling ongoing spray parameters to spray-form an article having a mixed-phase and interspersed makeup of metallic phases that minimizes residual stress in the article.Type: GrantFiled: November 27, 2001Date of Patent: June 14, 2005Assignee: Ford Motor CompanyInventors: Allen Dennis Roche, Samir Samir, Chijoke Mgbokwere, Mark Lusk
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Method and arrangement for implementing heat treatment during the execution of spray-form techniques
Patent number: 6883581Abstract: A method for implementing post-heat treatment during spray forming to achieve stress control in the manufacture of a spray formed metallic tool involves applying a metallic spray-forming material onto a mold substrate and causing substantially homogenous metallic phase transformations from the austenite phase, for example, via manipulation of either or both of the substrate temperature and the spray forming cell environment temperature.Type: GrantFiled: November 27, 2001Date of Patent: April 26, 2005Assignee: Ford Motor CompanyInventors: Allen Dennis Roche, Samir Samir, Chijoke Mgbokwere, Mark Lusk -
Publication number: 20040219383Abstract: The present invention relates to a method of spray forming a boron steel metal article, and to the formed article. In at least one embodiment, the method comprises (a) providing a spray forming pattern, (b) spraying metallic particles onto the spray forming pattern, and (c) allowing the sprayed metallic particles to cool to form a metal article. In at least one embodiment, the metallic particles are sprayed from a carbon steel feedstock having a boron content of 0.25-2.25 weight percent, based on the total weight of the feedstock.Type: ApplicationFiled: June 25, 2004Publication date: November 4, 2004Applicant: FORD MOTOR COMPANYInventors: Allen Dennis Roche, David Robert Collins, Richard L. Allor
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Patent number: 6810939Abstract: The present invention relates to a method of spray forming a boron steel metal article, and to the formed article. In at least one embodiment, the method comprises (a) providing a spray forming pattern, (b) spraying metallic particles onto the spray forming pattern, and (c) allowing the sprayed metallic particles to cool to form a metal article. In at least one embodiment, the metallic particles are sprayed from a carbon steel feedstock having a boron content of 0.25-2.25 weight percent, based on the total weight of the feedstock.Type: GrantFiled: February 4, 2003Date of Patent: November 2, 2004Assignee: Ford Motor CompanyInventors: Allen Dennis Roche, David Robert Collins, Richard L. Allor
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Patent number: 6805949Abstract: One method of the present invention relates to a method for enhancing adhesion of spraying metal to a ceramic model. The method is comprised of providing the ceramic model having a spray surface, and modifying at least a portion of the spray surface if the ceramic model to enhance adhesion of spray metal to the spray surface.Type: GrantFiled: March 25, 2003Date of Patent: October 19, 2004Assignee: Ford Motor CompanyInventors: Allen Dennis Roche, John Michael Nicholson, Richard L. Allor, David Warren Worthey
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Patent number: 6805188Abstract: A method for implementing pre-heat treatment before spray forming begins to achieve stress control in the manufacture of a spray formed metallic article involves preheating either or both of a spray forming cell environment and a mold substrate, initiating application of the metallic spray forming material onto the mold substrate, and causing substantially homogenous initial metallic phase transformations from the austenite phase via a predetermined relationship between the initial application temperature of the spray-forming material and the initial temperature of either or both of the preheated cell environment and the preheated mold substrate.Type: GrantFiled: November 27, 2001Date of Patent: October 19, 2004Assignee: Ford Global Technologies, LLCInventors: Allen Dennis Roche, Joseph A. Szuba, Samir Samir, Chijoke Mgbokwere
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Publication number: 20040191543Abstract: One method of the present invention relates to a method for enhancing adhesion of sprayed metal to a ceramic model. The method is comprised of providing the ceramic model having a spray surface, and modifying at least a portion of the spray surface of the ceramic model to enhance adhesion of spray metal to the spray surface.Type: ApplicationFiled: March 25, 2003Publication date: September 30, 2004Applicant: FORD MOTOR COMPANYInventors: Allen Dennis Roche, John Michael Nicholson, Richard L. Allor, David Warren Worthey
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Patent number: 6796366Abstract: One method of the present invention includes introducing a slurry into a mold unit comprised of a mold contained within a casting receptacle and lowering the temperature of the slurry to freeze the slurry and form a freeze-cast substrate while controlling temperature gradients within the mold unit to minimize distortion in the freeze-cast substrate. Another method includes introducing a slurry into a mold unit comprised of a mold contained within a casting receptacle, placing insulation material around at least a portion of the casting receptacle to minimize distortion in the freeze-cast substrate by controlling temperature gradients within the mold unit, and lowering the temperature of the slurry to freeze the slurry to form a freeze-cast substrate.Type: GrantFiled: October 30, 2002Date of Patent: September 28, 2004Assignee: Ford Motor CompanyInventors: Allen Dennis Roche, John Michael Nicholson, Richard L. Allor, Samir Samir
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Patent number: 6777035Abstract: One method of the present invention relates to a method for spray forming metal deposits. The method is comprised of providing a ceramic substrate having a spraying pattern for receiving sprayed metal particles, spraying metal particles onto the spraying pattern to form a metal deposit on the spraying pattern for at least a first spray period, controlling the spraying step during the first spray period so that the temperature of the deposited metal particles increases at an average rate of less than or equal to about 15° per minute. The first spray period can be defined as lasting until the temperature of the deposited metal particles is at or about a steady state temperature. The steady state temperature is preferably in the range of about 330° C. to about 370° C.Type: GrantFiled: February 10, 2003Date of Patent: August 17, 2004Assignee: Ford Motor CompanyInventors: Grigoriy Grinberg, Allen Dennis Roche, David Robert Collins, Richard L Allor
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Publication number: 20040157001Abstract: One method of the present invention relates to a method for spray forming metal deposits. The method is comprised of providing a ceramic substrate having a spraying pattern for receiving sprayed metal particles, spraying metal particles onto the spraying pattern to form a metal deposit on the spraying pattern for at least a first spray period, controlling the spraying step during the first spray period so that the temperature of the deposited metal particles increases at an average rate of less than or equal to about 15° per minute. The first spray period can be defined as lasting until the temperature of the deposited metal particles is at or about a steady state temperature. The steady state temperature is preferably in the range of about 330° C. to about 370° C.Type: ApplicationFiled: February 10, 2003Publication date: August 12, 2004Applicant: FORD MOTOR COMPANYInventors: Grigoriy Grinberg, Allen Dennis Roche, David Robert Collins, Richard L. Allor
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Publication number: 20040149417Abstract: The present invention relates to a method of spray forming a boron steel metal article, and to the formed article. In at least one embodiment, the method comprises (a) providing a spray forming pattern, (b) spraying metallic particles onto the spray forming pattern, and (c) allowing the sprayed metallic particles to cool to form a metal article. In at least one embodiment, the metallic particles are sprayed from a carbon steel feedstock having a boron content of 0.25-2.25 weight percent, based on the total weight of the feedstock.Type: ApplicationFiled: February 4, 2003Publication date: August 5, 2004Applicant: FORD MOTOR COMPANYInventors: Allen Dennis Roche, David Robert Collins, Richard L. Allor
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Publication number: 20040084169Abstract: One method of the present invention includes introducing a slurry into a mold unit comprised of a mold contained within a casting receptacle and lowering the temperature of the slurry to freeze the slurry and form a freeze-cast substrate while controlling temperature gradients within the mold unit to minimize distortion in the freeze-cast substrate. Another method includes introducing a slurry into a mold unit comprised of a mold contained within a casting receptacle, placing insulation material around at least a portion of the casting receptacle to minimize distortion in the freeze-cast substrate by controlling temperature gradients within the mold unit, and lowering the temperature of the slurry to freeze the slurry to form a freeze-cast substrate.Type: ApplicationFiled: October 30, 2002Publication date: May 6, 2004Applicant: Ford Motor CompanyInventors: Allen Dennis Roche, John Michael Nicholson, Richard L. Allor, Samir Samir
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Patent number: 6675625Abstract: The present invention discloses a method of correcting the shape of a spray-formed article which has a concave bowing relative to the working surface of the article. Specifically, deviations of such articles from a desired predetermined shape are corrected by applying sufficient heat to a non-working surface to permanently remove at least a partial amount of the concave bowing while leaving the working surface substantially unmarred. This process is repeated iteratively until the article achieves the predetermined shape.Type: GrantFiled: November 11, 2002Date of Patent: January 13, 2004Assignee: Ford Motor CompanyInventors: Allen Dennis Roche, Sankaran Subramaniam
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Patent number: 6623808Abstract: A process for producing a metallic tool, mould, die or other body of significant thickness or a coating, the process comprising directing a spray (3, 4) comprising molten metallic droplets carried by a propelling gas toward an object surface (7) of a substrate or pattern (5) so as to build up a metallic deposit or coating comprising the mould, tool, die, body or coating on the object surface (7) of the substrate or pattern (5), wherein at one or more predetermined stages during spraying droplets of a relatively large mean size are sprayed and at one or more other stages droplets or a relatively smaller mean size are sprayed.Type: GrantFiled: February 1, 2002Date of Patent: September 23, 2003Assignees: Ford Global Technologies, Inc., Sprayform Holdings LimitedInventors: Richard Michael Jordan, Jonathan Betts, Patrick Grant, Allen Dennis Roche, Piers Newbery
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Publication number: 20030098341Abstract: A method for implementing post-heat treatment during spray forming to achieve stress control in the manufacture of a spray formed metallic tool involves applying a metallic spray-forming material onto a mold substrate and causing substantially homogenous metallic phase transformations from the austenite phase, for example, via manipulation of either or both of the substrate temperature and the spray forming cell environment temperature.Type: ApplicationFiled: November 27, 2001Publication date: May 29, 2003Applicant: Ford Motor CompanyInventors: Allen Dennis Roche, Samir Samir, Chijoke Mgbokwere, Mark Lusk
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Publication number: 20030098138Abstract: A method and arrangement for implementing post-heat treatment after spray forming is ended to achieve stress control in the manufacture of a spray formed metallic tool involves providing a spray-formed metallic tool by applying a spray-forming material on a mold substrate and causing substantially homogenous metallic phase transformations of the spray forming material within the spray-formed metallic tool to a substantially homogenous distribution of commingled metallic phases consisting, for example, of predetermined proportions of at least a bainite phase and a martinsite phase.Type: ApplicationFiled: November 27, 2001Publication date: May 29, 2003Applicant: Ford Motor CompanyInventors: Richard L. Allor, Allen Dennis Roche, Samir Samir