Patents by Inventor Edward K. Steinebach
Edward K. Steinebach 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: 20230088978Abstract: The invention provides a component formed of an aluminum alloy for use in a vehicle, for example an automotive vehicle component requiring high strength, light-weight, and a complex three-dimensional shape, and a method of manufacturing the component. The method begins by providing a blank formed of an aluminum alloy which is already solution heat treated and tempered, and thus has a temper designation of about T4. The method further includes heating the blank to a temperature of 150° C. to 350° C., preferably 190° C. to 225° C. The method next includes quickly transferring the blank to a hot or warm forming apparatus, and stamping the blank to form the complex three-dimensional shape. Immediately after the forming step, the component has a temper designation of about T6, but preferably not greater than T6, and thus is ready for use in the vehicle without any post heat treatment or machining.Type: ApplicationFiled: November 28, 2022Publication date: March 23, 2023Inventors: Edward K. STEINEBACH, Mark Justin JONES, Jeremiah John BRADY, Kenneth Ray ADAMS, Gerard M. LUDTKA
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Patent number: 11607747Abstract: The present invention relates generally to laser welding in the manufacture of sheet metal components, such as for example automobile components. More particularly, the present invention relates to a process and a system for forming a localized anti-corrosion surface layer along a laser welded joint (weld bead), subsequent to the laser welding together of sheet metal plates having an anti-corrosion surface layer pre-coat.Type: GrantFiled: February 3, 2020Date of Patent: March 21, 2023Assignee: MAGNA INTERNATIONAL INC.Inventors: Hongping Gu, Aldo Anthony Van Gelder, Jeremiah John Brady, Edward K. Steinebach, Mark Justin Jones
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Publication number: 20200370155Abstract: The invention provides a component formed of an aluminum alloy for use in a vehicle, for example an automotive vehicle component requiring high strength, light-weight, and a complex three-dimensional shape, and a method of manufacturing the component. The method begins by providing a blank formed of an aluminum alloy which is already solution heat treated and tempered, and thus has a temper designation of about T4. The method further includes heating the blank to a temperature of 150° C. to 350° C., preferably 190° C. to 225° C. The method next includes quickly transferring the blank to a hot or warm forming apparatus, and stamping the blank to form the complex three-dimensional shape. Immediately after the forming step, the component has a temper designation of about T6, but preferably not greater than T6, and thus is ready for use in the vehicle without any post heat treatment or machining.Type: ApplicationFiled: August 10, 2020Publication date: November 26, 2020Inventors: Edward K. STEINEBACH, Mark Justin JONES, Jeremiah John BRADY, Kenneth Ray ADAMS, Gerard M. LUDTKA
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Patent number: 10774408Abstract: The invention provides a method of manufacturing a component formed of an aluminum alloy for use in an automotive vehicle application, for example those requiring high strength, light-weight, and a complex three-dimensional shape. The method begins by providing a blank formed of an aluminum alloy which is already solution heat treated and tempered, and thus has a temper designation of about T4. The method further includes heating the blank to a temperature of 150° C. to 350° C., preferably 190° C. to 225° C. The method next includes quickly transferring the blank to a hot or warm forming apparatus, and stamping the blank to form the complex three-dimensional shape. Immediately after the forming step, the component has a temper designation of about T6, but preferably not greater than T6, and thus is ready for use in the automotive vehicle application without any post heat treatment or machining.Type: GrantFiled: January 23, 2015Date of Patent: September 15, 2020Assignee: MAGNA INTERNATIONAL INC.Inventors: Edward K. Steinebach, Mark Justin Jones, Jeremiah John Brady, Kenneth Ray Adams, Gerard M. Ludtka
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Publication number: 20200180078Abstract: A process is described for laser welding a sheet metal workpiece having an anti-corrosion pre-coat material on at least one major surface thereof. The sheet metal workpiece is arranged such that first and second side edges are in contact with one another and the coated major surface faces outwardly. A first laser beam having a first beam spot-size is used to form a laser weld joint between the first and second side edges. A second laser beam having a second beam spot-size larger than the first beam spot-size is then scanned along the laser weld joint and is tilted in a tilt direction parallel to the scanning direction to produce an elongated beam spot. During the scanning, a flow of a powdered anti-corrosion surface layer material is directed toward a portion of the laser weld joint that is being irradiated by the second laser beam. The second laser beam melts the material, which forms a layer adhering to the laser weld joint.Type: ApplicationFiled: February 3, 2020Publication date: June 11, 2020Inventors: Hongping Gu, Aldo Anthony Van Gelder, Jeremiah John Brady, Edward K. Steinebach, Mark Justin Jones
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Patent number: 10583528Abstract: A process is described for laser welding a sheet metal workpiece having an anti-corrosion pre-coat on at least one major surface thereof and having first and second opposite side edges. The sheet metal workpiece is arranged such that the first and second side edges are in contact with one another and such that the at least one major surface faces outwardly. A laser beam having a first beam spot-size, is used to form a laser weld joint between the first and second side edges. Subsequently, a localized anti-corrosion surface layer is formed on the laser weld joint. To this end, a laser beam having a second beam spot-size larger than the first beam spot-size is scanned along the laser weld joint. During the scanning, a flow of a powdered anti-corrosion surface layer material is directed toward a portion of the laser weld joint that is being irradiated by the laser beam. The laser beam melts the material, which subsequently solidifies to form a layer adhering to the laser weld joint.Type: GrantFiled: May 27, 2016Date of Patent: March 10, 2020Assignee: Magna International Inc.Inventors: Hongping Gu, Aldo Anthony Van Gelder, Jeremiah John Brady, Edward K. Steinebach, Mark Justin Jones
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Patent number: 10293771Abstract: A vehicle bumper assembly includes a bumper beam and a crash box. At least one of the bumper beam or the crash box is cast from metal, such as aluminum or magnesium, to reduce weight, reduce manufacturing process steps, and improve performance characteristics of the bumper assembly. In an embodiment, both of the bumper beam and the crash box are cast from metal to establish an integral connection therebetween. One of the bumper beam or the crash box can be open along a top and bottom portion of the bumper assembly and include at least one reinforcing rib cast integral therewith. In an embodiment, both of the bumper beam and the crash box can be open along a top and bottom portion of the bumper assembly and each include at least one reinforcing rib cast integral therewith.Type: GrantFiled: July 8, 2015Date of Patent: May 21, 2019Assignee: MAGNA INTERNATIONAL INC.Inventors: Edward K. Steinebach, Mark Justin Jones, Jeffrey Jay Mellis, Jeremiah John Brady, Richard Lee Winfree, Warren Edward Young, Erryn Leigh Ashmore, Darren Andrew Womack, Venugopal Garimella, Paul James Marston
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Patent number: 10202091Abstract: A bumper beam system is provided that includes a bumper beam that is cast from metal and has at least a first portion comprised of a first alloy and a second portion comprised of a second alloy that is different than the first alloy. Furthermore, a crash box is provided that comprises a first portion comprised of a first alloy and a second portion comprised of a second alloy that is different than the first alloy. Additionally, a bumper beam system is provided that has a bumper beam and a crash box. The bumper beam includes at least a first bumper beam portion that is comprised of a first bumper beam alloy, and the crash box includes at least a first crash box portion that is comprised of a first crash box alloy. Methods of manufacturing the bumper beam system and crash boxes are also provided.Type: GrantFiled: December 21, 2016Date of Patent: February 12, 2019Assignee: Magna International Inc.Inventors: Edward K. Steinebach, Jeffrey Jay Mellis, Jeremiah John Brady, Richard Lee Winfree
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Patent number: 10052720Abstract: A process is disclosed for laser-welding sheet metal plates that have an aluminum-silicon containing pre-coat layer. The pre-coated sheet metal plates are arranged one relative to another such that an edge of one of the plates is adjacent to and in contact with an edge of the other one of the plates, and a laser-welded joint is formed along the adjacent edges of the pre-coated plates. In particular the joint is formed absent removing the aluminum-silicon containing layer from along the adjacent edges, such that aluminum from the aluminum-silicon containing layer enters into the melt pool that is formed. Additionally, an alloying material is introduced into the melt pool during forming the laser-welded joint and forms a compound with at least some of the aluminum in the melt pool.Type: GrantFiled: September 15, 2015Date of Patent: August 21, 2018Assignee: Magna International Inc.Inventors: Hongping Gu, Aldo Van Gelder, Jeremiah John Brady, Edward K. Steinebach, Mark Justin Jones
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Patent number: 10052721Abstract: A process is described for laser welding a sheet metal workpiece having an aluminum-silicon containing pre-coat layer disposed on at least one major surface thereof, and having first and second opposite side edges. The sheet metal workpiece is arranged such that the first and second side edges are in contact with one another and such that the at least one major surface faces outwardly. A closed tube-shaped product is obtained by forming a laser-weld joint between the first and second side edges. In particular the laser-weld joint is formed absent removing the aluminum-silicon containing layer from along the adjacent edges, such that aluminum from the aluminum-silicon containing layer enters into the melt pool that is formed. An alloying material is introduced into the melt pool during laser welding and forms a compound with at least some of the aluminum in the melt pool.Type: GrantFiled: July 12, 2016Date of Patent: August 21, 2018Assignee: Magna International Inc.Inventors: Hongping Gu, Aldo Van Gelder, Jeremiah John Brady, Edward K. Steinebach, Mark Justin Jones
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Publication number: 20170298462Abstract: The invention relates generally to structural steel components for automotive vehicles, and methods for manufacturing the structural components. The method includes heating a workpiece to at least 900° C. to form austenite in the steel material, hot forming the workpiece, and quenching the formed workpiece to transform the austenite to martensite. The method next includes tempering at least one portion of the quenched workpiece, wherein the tempering step includes simultaneously applying thermal energy and a magnetic field to the workpiece. During the tempering step, the martensite of the steel material transforms to a mixture of ferrite and cementite precipitates. The portions of the steel material subject to the thermomagnetic tempering are also typically free of pearlite and spheroid particles. The remainder of the workpiece is protected during the tempering step to maintain a hard zone including the martensite.Type: ApplicationFiled: September 18, 2015Publication date: October 19, 2017Inventors: Richard Lee WINFREE, Edward K. STEINEBACH, Mark Justin JONES, Jeremiah John BRADY, Kenneth Ray ADAMS, Gerard M. LUDTKA, Kenneth James THERRIEN
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Publication number: 20170136970Abstract: A vehicle bumper assembly includes a bumper beam and a crash box. At least one of the bumper beam or the crash box is cast from metal, such as aluminum or magnesium, to reduce weight, reduce manufacturing process steps, and improve performance characteristics of the bumper assembly. In an embodiment, both of the bumper beam and the crash box are cast from metal to establish an integral connection therebetween. One of the bumper beam or the crash box can be open along a top and bottom portion of the bumper assembly and include at least one reinforcing rib cast integral therewith. In an embodiment, both of the bumper beam and the crash box can be open along a top and bottom portion of the bumper assembly and each include at least one reinforcing rib cast integral therewith.Type: ApplicationFiled: July 8, 2015Publication date: May 18, 2017Inventors: Edward K. Steinebach, Mark Justin Jones, Jeffrey Jay Mellis, Jeremiah John Brady, Richard Lee Winfree, Warren Edward Young, Erryn Leigh Ashmore, Darren Andrew Womack, Venugopal Garimella, Paul James Marston
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Publication number: 20170106822Abstract: A bumper beam system is provided that includes a bumper beam that is cast from metal and has at least a first portion comprised of a first alloy and a second portion comprised of a second alloy that is different than the first alloy. Furthermore, a crash box is provided that comprises a first portion comprised of a first alloy and a second portion comprised of a second alloy that is different than the first alloy. Additionally, a bumper beam system is provided that has a bumper beam and a crash box. The bumper beam includes at least a first bumper beam portion that is comprised of a first bumper beam alloy, and the crash box includes at least a first crash box portion that is comprised of a first crash box alloy. Methods of manufacturing the bumper beam system and crash boxes are also provided.Type: ApplicationFiled: December 21, 2016Publication date: April 20, 2017Inventors: Edward K. Steinebach, Jeffrey Jay Mellis, Jeremiah John Brady, Richard Lee Winfree
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Publication number: 20160340766Abstract: The invention provides a method of manufacturing a component formed of an aluminum alloy for use in an automotive vehicle application, for example those requiring high strength, light-weight, and a complex three-dimensional shape. The method begins by providing a blank formed of an aluminum alloy which is already solution heat treated and tempered, and thus has a temper designation of about T4. The method further includes heating the blank to a temperature of 150° C. to 350° C., preferably 190° C. to 225° C. The method next includes quickly transferring the blank to a hot or warm forming apparatus, and stamping the blank to form the complex three-dimensional shape. Immediately after the forming step, the component has a temper designation of about T6, but preferably not greater than T6, and thus is ready for use in the automotive vehicle application without any post heat treatment or machining.Type: ApplicationFiled: January 23, 2015Publication date: November 24, 2016Inventors: Edward K. Steinebach, Mark Justin Jones, Jeremiah John Brady, Kenneth Ray Adams, Gerard M. Ludtka
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Publication number: 20160332256Abstract: A process is disclosed for laser-welding sheet metal plates that have an aluminum-silicon containing pre-coat layer. The pre-coated sheet metal plates are arranged one relative to another such that an edge of one of the plates is adjacent to and in contact with an edge of the other one of the plates, and a laser-welded joint is formed along the adjacent edges of the pre-coated plates. In particular the joint is formed absent removing the aluminum-silicon containing layer from along the adjacent edges, such that aluminum from the aluminum-silicon containing layer enters into the melt pool that is formed. Additionally, an alloying material is introduced into the melt pool during forming the laser-welded joint and forms a compound with at least some of the aluminum in the melt pool.Type: ApplicationFiled: September 15, 2015Publication date: November 17, 2016Inventors: Hongping Gu, Aldo Van Gelder, Jeremiah John Brady, Edward K. Steinebach, Mark Justin Jones
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Publication number: 20160318127Abstract: A process is described for laser welding a sheet metal workpiece having an aluminum-silicon containing pre-coat layer disposed on at least one major surface thereof, and having first and second opposite side edges. The sheet metal workpiece is arranged such that the first and second side edges are in contact with one another and such that the at least one major surface faces outwardly. A closed tube-shaped product is obtained by forming a laser-weld joint between the first and second side edges. In particular the laser-weld joint is formed absent removing the aluminum-silicon containing layer from along the adjacent edges, such that aluminum from the aluminum-silicon containing layer enters into the melt pool that is formed. An alloying material is introduced into the melt pool during laser welding and forms a compound with at least some of the aluminum in the melt pool.Type: ApplicationFiled: July 12, 2016Publication date: November 3, 2016Inventors: Hongping Gu, Aldo Van Gelder, Jeremiah John Brady, Edward K. Steinebach, Mark Justin Jones
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Publication number: 20160271730Abstract: A process is described for laser welding a sheet metal workpiece having an anti-corrosion pre-coat on at least one major surface thereof and having first and second opposite side edges. The sheet metal workpiece is arranged such that the first and second side edges are in contact with one another and such that the at least one major surface faces outwardly. A laser beam having a first beam spot-size, is used to form a laser weld joint between the first and second side edges. Subsequently, a localized anti-corrosion surface layer is formed on the laser weld joint. To this end, a laser beam having a second beam spot-size larger than the first beam spot-size is scanned along the laser weld joint. During the scanning, a flow of a powdered anti-corrosion surface layer material is directed toward a portion of the laser weld joint that is being irradiated by the laser beam. The laser beam melts the material, which subsequently solidifies to form a layer adhering to the laser weld joint.Type: ApplicationFiled: May 27, 2016Publication date: September 22, 2016Inventors: Hongping Gu, Aldo Anthony Van Gelder, Jeremiah John Brady, Edward K. Steinebach, Mark Justin Jones
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Publication number: 20160244855Abstract: A method for manufacturing a hot formed part (20), such an automotive body component, is provided. The method includes heating a steel blank (22) to an austenite temperature, and quickly transferring the heated blank (22) to a hot forming apparatus (28). The method then includes forming the heated blank (22) between a pair of dies (24, 26), and trimming, piercing, shearing, or otherwise cutting the heated blank (22) or hot formed part (20) in the hot forming apparatus (28). The cutting step occurs while the microstructure of the steel blank (22) is substantially austenite, for example at a temperature of 400° C. to 850° C. The method can provide a hot formed part (20) having a desired shape in a single die stroke, without the need for a costly post-forming operation outside of the hot forming apparatus (28), such as laser trimming.Type: ApplicationFiled: October 21, 2014Publication date: August 25, 2016Inventors: Edward K. Steinebach, Mark Justin Jones, Jeremiah John Brady, Kenneth R. Adams