Patents by Inventor Charles Alan Rocco

Charles Alan Rocco 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).

  • Patent number: 11155057
    Abstract: A blow molded part is provided that includes a first portion consisting of a reinforced resin and a second portion consisting of a non-reinforced resin. The reinforced resin may be fiber-reinforced, and the non-reinforced resin may be a neat resin. In one form, the first portion and the second portion define first and second trim areas, respectively, and the second trim area is directly recyclable. In another form, the second portion comprises a material consisting of a non-reinforced resin and/or a reinforced resin, where the modulus of elasticity of the first portion is higher than the modulus of elasticity of the second portion. Furthermore, a method of forming a blow molded part is provided.
    Type: Grant
    Filed: June 14, 2017
    Date of Patent: October 26, 2021
    Assignee: Ford Global Technologies, LLC
    Inventors: Bernard Gerard Marchetti, Charles Alan Rocco
  • Publication number: 20180361626
    Abstract: A blow molded part is provided that includes a first portion consisting of a reinforced resin and a second portion consisting of a non-reinforced resin. The reinforced resin may be fiber-reinforced, and the non-reinforced resin may be a neat resin. In one form, the first portion and the second portion define first and second trim areas, respectively, and the second trim area is directly recyclable. In another form, the second portion comprises a material consisting of a non-reinforced resin and/or a reinforced resin, where the modulus of elasticity of the first portion is higher than the modulus of elasticity of the second portion. Furthermore, a method of forming a blow molded part is provided.
    Type: Application
    Filed: June 14, 2017
    Publication date: December 20, 2018
    Applicant: Ford Global Technologies, LLC
    Inventors: Bernard Gerard Marchetti, Charles Alan Rocco
  • Publication number: 20180290515
    Abstract: Blow molded components and systems and methods for forming the same are disclosed. The blow molded component may be an air duct, for example, a structural air duct. The structural air duct may include a hollow main body including a first layer of a first material and a second layer of a second material surrounding the first layer. At least one hollow protrusion may extend from the hollow main body and may include proximal and distal portions. The proximal portion may include the first layer surrounded by the second layer and the distal portion may include only one of the first and second layers. The duct may be formed by blow molding a multi-material parison. The first and second materials may have different tensile moduli, and during the molding process the material with the higher modulus may tear and allow the lower modulus material to fill the protrusion.
    Type: Application
    Filed: April 11, 2017
    Publication date: October 11, 2018
    Inventors: Bernard Gerard MARCHETTI, Charles Alan ROCCO, Dan G. BUSUIOC, Timothy R. BEARD
  • Patent number: 9956749
    Abstract: According to one or more embodiments, a polymeric article includes a first polymeric layer defining a first portion and a second portion, the first portion having a first side and a second side opposing the first side, the first side being exposed to atmospheric air, and an ink layer and a second polymeric layer, the ink layer being positioned between the second polymeric layer and the second portion of the first polymeric layer.
    Type: Grant
    Filed: January 13, 2014
    Date of Patent: May 1, 2018
    Assignee: Ford Global Technologies, LLC
    Inventors: James Paul Yizze, III, Bernard Gerard Marchetti, Charles Alan Rocco
  • Publication number: 20170246782
    Abstract: A method is provided for molding a composite sheet in an injection molding press including a female mold tool and a cooperating male mold tool. The method includes the steps of loading the composite sheet into an open mold, positioning a heating element between the composite sheet and the female mold tool to preheat the composite sheet and a cavity of the female mold tool and removing the heating element and closing the mold.
    Type: Application
    Filed: March 12, 2015
    Publication date: August 31, 2017
    Inventors: Jeffery N. Conley, Charles Alan Rocco
  • Publication number: 20160263800
    Abstract: A method is provided for molding a composite sheet in an injection molding press including a female mold tool and a cooperating male mold tool. The method includes the steps of loading the composite sheet into an open mold, positioning a heating element between the composite sheet and the female mold tool to preheat the composite sheet and a cavity of the female mold tool and removing the heating element and closing the mold.
    Type: Application
    Filed: March 12, 2015
    Publication date: September 15, 2016
    Inventors: Jeffery N. Conley, Charles Alan Rocco
  • Publication number: 20160193902
    Abstract: A sun visor for a vehicle includes a visor body, a minor carried on the visor body and a cover overlying the minor. A control module controls operation of the cover and switches the cover between an opaque state wherein the mirror is hidden from view and a transparent state wherein the mirror is visible to view and available for use.
    Type: Application
    Filed: January 5, 2015
    Publication date: July 7, 2016
    Inventors: Anna Miller Hill, Neal Randolph Osstyn, Peter David Alexander Jones, Charles Alan Rocco
  • Publication number: 20150197046
    Abstract: The present invention in one or more embodiments provides a method of forming a polymeric skin of a vehicle interior part such as an instrument panel, the method including the steps of heating a molding cavity having a shape of the vehicle interior part, injecting a polymer into the molding cavity to form the polymeric skin, and cooling the molding cavity. The heating may be carried out prior to the injecting. The heating may overlap in time with the injecting. The cooling may be carried out subsequent to the injecting. The cooling may overlap in time with the injecting. The polymeric skin may then positioned next to a cushion layer which is in turn positioned next to a substrate layer to form the vehicle interior part.
    Type: Application
    Filed: January 16, 2014
    Publication date: July 16, 2015
    Applicant: Ford Global Technologies, LLC
    Inventors: James Paul Yizze, Bari Brown, Charles Alan Rocco
  • Publication number: 20150197075
    Abstract: According to one or more embodiments, a polymeric article includes a first polymeric layer defining a first portion and a second portion, the first portion having a first side and a second side opposing the first side, the first side being exposed to atmospheric air, and an ink layer and a second polymeric layer, the ink layer being positioned between the second polymeric layer and the second portion of the first polymeric layer.
    Type: Application
    Filed: January 13, 2014
    Publication date: July 16, 2015
    Applicant: Ford Global Technologies, LLC
    Inventors: James Paul Yizze, III, Bernard Gerard Marchetti, Charles Alan Rocco
  • Patent number: 8627876
    Abstract: A mold core package for forming a molding tool includes a plurality of stacked particulate layers having a binding agent. The plurality of stacked particulate layers form sacrificial walls defining a mold cavity. A sacrificial displacement line and a sacrificial displacement body extend from the mold core package and are adapted to displace a molten material applied to the mold core package.
    Type: Grant
    Filed: February 29, 2012
    Date of Patent: January 14, 2014
    Assignee: Ford Global Technologies, LLC
    Inventors: Charles Alan Rocco, Jeffery N. Conley, Raymond Edward Kalisz, Bernie Gerard Marchetti, Larry Edward Ellis, Harold P. Sears, James Todd Kloeb, Alan Lawrence Jacobson, Ronald Hasenbusch
  • Patent number: 8567477
    Abstract: A mold core package for forming a molding tool includes a plurality of stacked particulate layers having a binding agent. The plurality of stacked particulate layers form sacrificial walls. An elongate sacrificial displacement line extends through the mold core package adjacent a forming surface of the mold core package. A mold cavity is defined by the stacked particulate layers.
    Type: Grant
    Filed: February 29, 2012
    Date of Patent: October 29, 2013
    Assignee: Ford Global Technologies, LLC
    Inventors: Charles Alan Rocco, Jeffery N. Conley, Raymond Edward Kalisz, Bernie Gerard Marchetti, Larry Edward Ellis, Harold P. Sears, James Todd Kloeb, Alan Lawrence Jacobson, Ronald Hasenbusch
  • Publication number: 20130220572
    Abstract: A molding assembly for making molded parts includes a molding tool having conformal fluid lines that follow contours of a molding surface of the molding tool. The conformal fluid lines are defined in the molding tool during casting by sacrificial displacement lines formed by a three-dimensional printer. A temperature control station is coupled to the molding tool and includes a heating and cooling fluid. A valve station regulates fluid flow to the molding tool.
    Type: Application
    Filed: February 29, 2012
    Publication date: August 29, 2013
    Applicant: Ford Motor Company
    Inventors: Charles Alan Rocco, Raymond Edward Kalisz, Jeffery N. Conley, Bernie Gerard Marchetti
  • Publication number: 20130220573
    Abstract: A mold core package for forming a molding tool includes a plurality of stacked particulate layers having a binding agent. The plurality of stacked particulate layers form sacrificial walls defining a mold cavity. A sacrificial displacement line and a sacrificial displacement body extend from the mold core package and are adapted to displace a molten material applied to the mold core package.
    Type: Application
    Filed: February 29, 2012
    Publication date: August 29, 2013
    Applicant: Ford Motor Company
    Inventors: Charles Alan Rocco, Jeffery N. Conley, Raymond Edward Kalisz, Bernie Gerard Marchetti, Larry Edward Ellis, Harold P. Sears, James Todd Kloeb, Alan Lawrence Jacobson, Ronald Hasenbusch
  • Publication number: 20130221192
    Abstract: A mold core package for forming a molding tool with a removable insert includes a plurality of stacked particulate layers having a binding agent. The plurality of stacked particulate layers form molding pattern walls that generally define a base mold cavity and an insert mold cavity defining a mold surface. A sacrificial displacement line extends through the insert mold cavity closely following contours of the mold surface.
    Type: Application
    Filed: February 29, 2012
    Publication date: August 29, 2013
    Applicant: Ford Motor Company
    Inventors: Charles Alan Rocco, Raymond Edward Kalisz, Jeffery N. Conley, Bernie Gerard Marchetti
  • Publication number: 20130220569
    Abstract: A mold core package for forming a molding tool includes a plurality of stacked particulate layers having a binding agent. The plurality of stacked particulate layers form sacrificial walls. An elongate sacrificial displacement line extends through the mold core package adjacent a forming surface of the mold core package. A mold cavity is defined by the stacked particulate layers.
    Type: Application
    Filed: February 29, 2012
    Publication date: August 29, 2013
    Applicant: Ford Motor Company
    Inventors: Charles Alan Rocco, Jeffery N. Conley, Raymond Edward Kalisz, Bernie Gerard Marchetti, Larry Edward Ellis, Harold P. Sears, James Todd Kloeb, Alan Lawrence Jacobson, Roland Hasenbusch
  • Patent number: 8313939
    Abstract: A method of making a molded part, including forming a liquid aggregate from a mixture of ground aggregate and a fluid. A fungal inoculum and the liquid aggregate are injected into a first mold cavity. The first mold cavity is sealed against a second mold cavity. Live mycelium is grown from the fungal inoculum to fill the first and second mold cavities. The live mycelium is cured to terminate further growth and develop a formed substrate.
    Type: Grant
    Filed: June 9, 2010
    Date of Patent: November 20, 2012
    Assignee: Ford Global Technologies, Inc.
    Inventors: Raymond Edward Kalisz, Charles Alan Rocco, Elizabeth Cleary Johnston Tengler, Rosaria Lee Petrella-Lovasik
  • Patent number: 8297667
    Abstract: A lockable latch system includes an anchor bar rigidly connected to a vehicle and a rigid hook operably engaged with the anchor bar. A springboard is disposed on the rigid hook. The springboard is operable between an obstructing position, wherein the springboard prevents disengagement of the rigid hook from the bar and an unobstructing position, wherein the springboard does not prevent disengagement of the rigid hook from the bar. A lock assembly includes a cam operable between an interference position, wherein the cam prevents the springboard from entering the unobstructing position and a non-interference position, wherein the cam does not prevent the springboard from entering the unobstructing position.
    Type: Grant
    Filed: June 8, 2009
    Date of Patent: October 30, 2012
    Assignee: Ford Global Technologies, LLC
    Inventors: Junko Pauken, Charles Alan Rocco, Michael James Whitens
  • Patent number: 8298809
    Abstract: A method of making a hardened elongate structure, including growing a live mycelium mat having branching hyphae. The live mycelium mat is layered to form a multi-layered structure. The hyphae are allowed to grow inward into the multi-layered structure such that the hyphae are interwoven throughout the multi-layered structure. The multi-layered structure is cured to terminate mycelium growth.
    Type: Grant
    Filed: June 9, 2010
    Date of Patent: October 30, 2012
    Assignee: Ford Global Technologies, LLC
    Inventors: Raymond Edward Kalisz, Charles Alan Rocco
  • Patent number: 8298810
    Abstract: A method of making a molded part, including adding a fungal inoculum with a liquid aggregate to form a mixture. The mixture is inserted into a mold cavity. The mold cavity is covered with a cover. Live mycelium is grown from the mixture that fills the mold cavity and physically couples with the cover. The live mycelium is heated to terminate further growth and develop a composite component made of mycelium and the cover.
    Type: Grant
    Filed: June 9, 2010
    Date of Patent: October 30, 2012
    Assignee: Ford Global Technologies, LLC
    Inventors: Charles Alan Rocco, Raymond Edward Kalisz
  • Patent number: 8283153
    Abstract: A method of making a molded part, including forming a liquid aggregate from a mixture of finely ground aggregate and a fluid. A mixture of a fungal inoculum and the liquid aggregate is formed. Nanoparticles are homogenously distributed throughout the mixture. The mixture is inserted into a mold cavity. Live mycelium is grown to fill the mold cavity. The live mycelium is heated to terminate further growth and develop a formed part.
    Type: Grant
    Filed: June 9, 2010
    Date of Patent: October 9, 2012
    Assignee: Ford Global Technologies, LLC
    Inventors: Charles Alan Rocco, Raymond Edward Kalisz