Patents by Inventor Calvin A. Saur
Calvin A. Saur 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: 20200189664Abstract: A load bearing panel member having a first portion, a second portion, and an appearance surface portion is formed by injection molding such that the first portion includes a plurality of ribs forming a grid pattern on the first portion and another plurality of ribs extending toward the periphery of the first portion which may be non-orthogonal to each other and to the ribs forming the grid pattern. An appearance surface portion attached to the first portion and second portion of the panel member forms an integral hinge between the first and second portions of the panel member. The panel member may be configured as a floor panel of a vehicle.Type: ApplicationFiled: February 21, 2020Publication date: June 18, 2020Applicant: Century Plastics, LLC d/b/a CIE USAInventors: Calvin A. Saur, Robert L. Becker
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Patent number: 10569809Abstract: A load bearing panel member having a first portion, a second portion, and an appearance surface portion is formed by injection molding such that the first portion includes a plurality of ribs forming a grid pattern on the first portion and another plurality of ribs extending toward the periphery of the first portion which may be non-orthogonal to each other and to the ribs forming the grid pattern. An internal channel may be formed within each of the non-orthogonal ribs by injecting a gas into the rib during the molding process forming the panel. An appearance surface portion attached to the first portion and second portion of the panel member forms an integral hinge between the first and second portions of the panel member. The panel member may be configured as a floor panel of a vehicle.Type: GrantFiled: March 22, 2018Date of Patent: February 25, 2020Assignee: Century Plastics, LLCInventors: Calvin A. Saur, Robert L. Becker
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Patent number: 10369937Abstract: A panel assembly includes a multilayer panel including first and second layers made of loftable material characterized by a molded orientation resultant from lofting and subsequently compressing the loftable material during molding of the multilayer panel. The panel assembly may be light-weight with a low profile to minimize protrusion into an opening or compartment enclosed by the panel. The multilayer panel may be configured to as a floor panel enclosing an opening defined by a floor structure, which may be a vehicle floor. The multilayer panel may include at least one recess portion configured to strengthen the multilayer panel. A method of making the multilayer panel includes tethering the loftable material in a tethering frame prior to lofting and transferring the tethering frame including the lofted material into a mold to form into the multilayer panel. The tethering frame retains offal for removal from the mold after forming the panel.Type: GrantFiled: December 3, 2015Date of Patent: August 6, 2019Assignee: Century Plastics, LLCInventors: Joseph W. Marchesano, Calvin A. Saur
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Publication number: 20180208249Abstract: A load bearing panel member having a first portion, a second portion, and an appearance surface portion is formed by injection molding such that the first portion includes a plurality of ribs forming a grid pattern on the first portion and another plurality of ribs extending toward the periphery of the first portion which may be non-orthogonal to each other and to the ribs forming the grid pattern. An internal channel may be formed within each of the non-orthogonal ribs by injecting a gas into the rib during the molding process forming the panel. An appearance surface portion attached to the first portion and second portion of the panel member forms an integral hinge between the first and second portions of the panel member. The panel member may be configured as a floor panel of a vehicle.Type: ApplicationFiled: March 22, 2018Publication date: July 26, 2018Applicant: Century Plastics, LLC d/b/a CIE USAInventors: Calvin A. Saur, Robert L. Becker
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Patent number: 9926016Abstract: A load bearing panel member having a first portion, a second portion, and an appearance surface portion is formed by injection molding such that the first portion includes a plurality of ribs forming a grid pattern on the first portion and another plurality of ribs extending toward the periphery of the first portion which may be non-orthogonal to each other and to the ribs forming the grid pattern. An internal channel may be formed within each of the non-orthogonal ribs by injecting a gas into the rib during the molding process forming the panel. An appearance surface portion attached to the first portion and second portion of the panel member forms an integral hinge between the first and second portions of the panel member. The panel member may be configured as a floor panel of a vehicle.Type: GrantFiled: March 2, 2017Date of Patent: March 27, 2018Assignee: Century Plastics, LLCInventors: Calvin A. Saur, Robert L. Becker
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Publication number: 20170174267Abstract: A load bearing panel member having a first portion, a second portion, and an appearance surface portion is formed by injection molding such that the first portion includes a plurality of ribs forming a grid pattern on the first portion and another plurality of ribs extending toward the periphery of the first portion which may be non-orthogonal to each other and to the ribs forming the grid pattern. An internal channel may be formed within each of the non-orthogonal ribs by injecting a gas into the rib during the molding process forming the panel. An appearance surface portion attached to the first portion and second portion of the panel member forms an integral hinge between the first and second portions of the panel member. The panel member may be configured as a floor panel of a vehicle.Type: ApplicationFiled: March 2, 2017Publication date: June 22, 2017Applicant: Century Plastics, Inc.Inventors: Calvin A. Saur, Robert L. Becker
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Patent number: 9616938Abstract: A load bearing panel member having a first portion, a second portion, and an appearance surface portion is formed by injection molding such that the first portion includes a plurality of ribs forming a grid pattern on the first portion and another plurality of ribs extending toward the periphery of the first portion which may be non-orthogonal to each other and to the ribs forming the grid pattern. An internal channel may be formed within each of the non-orthogonal ribs by injecting a gas into the rib during the molding process forming the panel. An appearance surface portion attached to the first portion and second portion of the panel member forms an integral hinge between the first and second portions of the panel member. The panel member may be configured as a floor panel of a vehicle.Type: GrantFiled: August 27, 2015Date of Patent: April 11, 2017Assignee: Century Plastics, Inc.Inventors: Calvin A. Saur, Robert L. Becker
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Publication number: 20160264067Abstract: A panel assembly includes at least one reinforcing assembly made of a high strength material having a low yield to tensile strength ratio for energy absorption and reduced weight and profile. The panel assembly may be light-weight with a low profile to minimize protrusion into an opening or compartment enclosed by the panel. The panel assembly may be a floor panel assembly for a vehicle floor. The reinforcing assembly may traverse the panel such that the reinforcing assembly extends laterally, e.g., cross-vehicle, relative to the longitudinal axis of the vehicle body. A method of making the panel assembly may include forming the reinforcing assembly by joining a plurality of metal channel members in a nested arrangement with a plurality of welds to provide a structural assembly with good bending resistance loads imposed on the panel assembly including knee loads. The channel members can be made of dual phase steel.Type: ApplicationFiled: May 20, 2016Publication date: September 15, 2016Applicant: Century Plastics, Inc.Inventors: Joseph W. Marchesano, Calvin A. Saur
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Patent number: 9358725Abstract: A panel assembly includes at least one reinforcing assembly made of a high strength material having a low yield to tensile strength ratio for energy absorption and reduced weight and profile. The panel assembly may be light-weight with a low profile to minimize protrusion into an opening or compartment enclosed by the panel. The panel assembly may be a floor panel assembly for a vehicle floor. The reinforcing assembly may traverse the panel such that the reinforcing assembly extends laterally, e.g., cross-vehicle, relative to the longitudinal axis of the vehicle body. A method of making the panel assembly may include forming the reinforcing assembly by joining a plurality of metal channel members in a nested arrangement with a plurality of welds to provide a structural assembly with good bending resistance loads imposed on the panel assembly including knee loads. The channel members can be made of dual phase steel.Type: GrantFiled: August 27, 2015Date of Patent: June 7, 2016Assignee: Century Plastics, Inc.Inventors: Joseph W. Marchesano, Calvin A. Saur
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Publication number: 20160082689Abstract: A panel assembly includes a multilayer panel including first and second layers made of loftable material characterized by a molded orientation resultant from lofting and subsequently compressing the loftable material during molding of the multilayer panel. The panel assembly may be light-weight with a low profile to minimize protrusion into an opening or compartment enclosed by the panel. The multilayer panel may be configured to as a floor panel enclosing an opening defined by a floor structure, which may be a vehicle floor. The multilayer panel may include at least one recess portion configured to strengthen the multilayer panel. A method of making the multilayer panel includes tethering the loftable material in a tethering frame prior to lofting and transferring the tethering frame including the lofted material into a mold to form into the multilayer panel. The tethering frame retains offal for removal from the mold after forming the panel.Type: ApplicationFiled: December 3, 2015Publication date: March 24, 2016Inventors: Joseph W. Marchesano, Calvin A. Saur
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Patent number: 9233490Abstract: A panel assembly includes a multilayer panel including first and second layers made of loftable material characterized by a molded orientation resultant from lofting and subsequently compressing the loftable material during molding of the multilayer panel. The panel assembly may be light-weight with a low profile to minimize protrusion into an opening or compartment enclosed by the panel. The multilayer panel may be configured to as a floor panel enclosing an opening defined by a floor structure, which may be a vehicle floor. The multilayer panel may include at least one recess portion configured to strengthen the multilayer panel. A method of making the multilayer panel includes tethering the loftable material in a tethering frame prior to lofting and transferring the tethering frame including the lofted material into a mold to form into the multilayer panel. The tethering frame retains offal for removal from the mold after forming the panel.Type: GrantFiled: August 1, 2014Date of Patent: January 12, 2016Assignee: Century Plastics, Inc.Inventors: Joseph W. Marchesano, Calvin A. Saur
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Publication number: 20150367564Abstract: A panel assembly includes at least one reinforcing assembly made of a high strength material having a low yield to tensile strength ratio for energy absorption and reduced weight and profile. The panel assembly may be light-weight with a low profile to minimize protrusion into an opening or compartment enclosed by the panel. The panel assembly may be a floor panel assembly for a vehicle floor. The reinforcing assembly may traverse the panel such that the reinforcing assembly extends laterally, e.g., cross-vehicle, relative to the longitudinal axis of the vehicle body. A method of making the panel assembly may include forming the reinforcing assembly by joining a plurality of metal channel members in a nested arrangement with a plurality of welds to provide a structural assembly with good bending resistance loads imposed on the panel assembly including knee loads. The channel members can be made of dual phase steel.Type: ApplicationFiled: August 27, 2015Publication date: December 24, 2015Inventors: Joseph W. Marchesano, Calvin A. Saur
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Publication number: 20150360730Abstract: A load bearing panel member having a first portion, a second portion, and an appearance surface portion is formed by injection molding such that the first portion includes a plurality of ribs forming a grid pattern on the first portion and another plurality of ribs extending toward the periphery of the first portion which may be non-orthogonal to each other and to the ribs forming the grid pattern. An internal channel may be formed within each of the non-orthogonal ribs by injecting a gas into the rib during the molding process forming the panel. An appearance surface portion attached to the first portion and second portion of the panel member forms an integral hinge between the first and second portions of the panel member. The panel member may be configured as a floor panel of a vehicle.Type: ApplicationFiled: August 27, 2015Publication date: December 17, 2015Inventors: Calvin A. Saur, Robert L. Becker
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Patent number: 9150255Abstract: A panel assembly includes at least one reinforcing assembly made of a high strength material having a low yield to tensile strength ratio for energy absorption and reduced weight and profile. The panel assembly may be light-weight with a low profile to minimize protrusion into an opening or compartment enclosed by the panel. The panel assembly may be a floor panel assembly for a vehicle floor. The reinforcing assembly may traverse the panel such that the reinforcing assembly extends laterally, e.g., cross-vehicle, relative to the longitudinal axis of the vehicle body. A method of making the panel assembly may include forming the reinforcing assembly by joining a plurality of metal channel members in a nested arrangement with a plurality of welds to provide a structural assembly with good bending resistance loads imposed on the panel assembly including knee loads. The channel members may be made of a dual phase steel.Type: GrantFiled: November 8, 2013Date of Patent: October 6, 2015Assignee: Century Plastics, Inc.Inventors: Joseph W. Marchesano, Calvin A. Saur
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Patent number: 9138922Abstract: A load bearing panel member having a first portion, a second portion, and an appearance surface portion is formed by injection molding such that the first portion includes a plurality of ribs forming a grid pattern on the first portion and another plurality of ribs extending toward the periphery of the first portion which may be non-orthogonal to each other and to the ribs forming the grid pattern. An internal channel may be formed within each of the non-orthogonal ribs by injecting a gas into the rib during the molding process forming the panel. An appearance surface portion attached to the first portion and second portion of the panel member forms an integral hinge between the first and second portions of the panel member. The panel member may be configured as a floor panel of a vehicle.Type: GrantFiled: May 19, 2014Date of Patent: September 22, 2015Assignee: Century Plastics, Inc.Inventors: Calvin A. Saur, Robert L. Becker
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Publication number: 20150054311Abstract: A panel assembly includes a multilayer panel including first and second layers made of loftable material characterized by a molded orientation resultant from lofting and subsequently compressing the loftable material during molding of the multilayer panel. The panel assembly may be light-weight with a low profile to minimize protrusion into an opening or compartment enclosed by the panel. The multilayer panel may be configured to as a floor panel enclosing an opening defined by a floor structure, which may be a vehicle floor. The multilayer panel may include at least one recess portion configured to strengthen the multilayer panel. A method of making the multilayer panel includes tethering the loftable material in a tethering frame prior to lofting and transferring the tethering frame including the lofted material into a mold to form into the multilayer panel. The tethering frame retains offal for removal from the mold after forming the panel.Type: ApplicationFiled: August 1, 2014Publication date: February 26, 2015Inventors: Joseph W. Marchesano, Calvin A. Saur
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Publication number: 20140252676Abstract: A load bearing panel member having a first portion, a second portion, and an appearance surface portion is formed by injection molding such that the first portion includes a plurality of ribs forming a grid pattern on the first portion and another plurality of ribs extending toward the periphery of the first portion which may be non-orthogonal to each other and to the ribs forming the grid pattern. An internal channel may be formed within each of the non-orthogonal ribs by injecting a gas into the rib during the molding process forming the panel. An appearance surface portion attached to the first portion and second portion of the panel member forms an integral hinge between the first and second portions of the panel member. The panel member may be configured as a floor panel of a vehicle.Type: ApplicationFiled: May 19, 2014Publication date: September 11, 2014Applicant: Century Plastics, Inc.Inventors: Calvin A. Saur, Robert L. Becker
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Patent number: 8764101Abstract: A load bearing panel member having a first portion, a second portion, and an appearance surface portion is formed by injection molding such that the first portion includes a plurality of rib members forming a grid pattern on the first portion and another plurality of rib members extending toward the periphery of the first portion which may be non-orthogonal to each other and to the rib members forming the grid pattern. A tubular cavity may be formed within each of the non-orthogonal rib members by injecting a gas into the rib member during the molding process forming the panel. An appearance surface portion attached to the first portion and second portion of the panel member forms an integral hinge between the first and second portions of the panel member. The panel member may be configured as a floor panel of a vehicle.Type: GrantFiled: June 12, 2012Date of Patent: July 1, 2014Assignee: Century Plastics, Inc.Inventors: Calvin A. Saur, Robert L. Becker
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Publication number: 20140062137Abstract: A panel assembly includes at least one reinforcing assembly made of a high strength material having a low yield to tensile strength ratio for energy absorption and reduced weight and profile. The panel assembly may be light-weight with a low profile to minimize protrusion into an opening or compartment enclosed by the panel. The panel assembly may be a floor panel assembly for a vehicle floor. The reinforcing assembly may traverse the panel such that the reinforcing assembly extends laterally, e.g., cross-vehicle, relative to the longitudinal axis of the vehicle body. A method of making the panel assembly may include forming the reinforcing assembly by joining a plurality of metal channel members in a nested arrangement with a plurality of welds to provide a structural assembly with good bending resistance loads imposed on the panel assembly including knee loads. The channel members may be made of a dual phase steel.Type: ApplicationFiled: November 8, 2013Publication date: March 6, 2014Applicant: Century Plastics, Inc.Inventors: Joseph W. Marchesano, Calvin A. Saur
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Publication number: 20120244309Abstract: A load bearing panel member having a first portion, a second portion, and an appearance surface portion is formed by injection molding such that the first portion includes a plurality of rib members forming a grid pattern on the first portion and another plurality of rib members extending toward the periphery of the first portion which may be non-orthogonal to each other and to the rib members forming the grid pattern. A tubular cavity may be formed within each of the non-orthogonal rib members by injecting a gas into the rib member during the molding process forming the panel. An appearance surface portion attached to the first portion and second portion of the panel member forms an integral hinge between the first and second portions of the panel member. The panel member may be configured as a floor panel of a vehicle.Type: ApplicationFiled: June 12, 2012Publication date: September 27, 2012Applicant: Centruy Plastics, Inc.Inventors: Calvin A. Saur, Robert L. Becker