Patents by Inventor Jay Mellis
Jay Mellis 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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Patent number: 11052845Abstract: A bumper system including a bumper beam being cast from metal having a front panel and a back panel, extending between a first bumper beam end and a second bumper beam end. A plurality of reinforcing ribs integrally cast with the bumper beam extends between the front panel and the back panel defining a non-uniform cross-sectional profile along a portion of the bumper beam. The front panel includes a front center portion disposed between a pair of front side portions. The back panel includes a back center portion disposed between a pair of back side portions. The front center portion has a front center portion thickness greater than a back center portion thickness. Each of the front side portions has a front side portion thickness being less than a back side portion thickness of adjacent one of the back side portions. Method of manufacturing the bumper system is provided.Type: GrantFiled: July 31, 2019Date of Patent: July 6, 2021Assignee: MAGNA INTERNATIONAL INC.Inventors: Edward Karl Steinebach, Jeremiah John Brady, Jeffrey Jay Mellis, Richard Lee Winfree, Mark Justin Jones, Darren Andrew Womack
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Publication number: 20190351855Abstract: A bumper system including a bumper beam being cast from metal having a front panel and a back panel, extending between a first bumper beam end and a second bumper beam end. A plurality of reinforcing ribs integrally cast with the bumper beam extends between the front panel and the back panel defining a non-uniform cross-sectional profile along a portion of the bumper beam. The front panel includes a front center portion disposed between a pair of front side portions. The back panel includes a back center portion disposed between a pair of back side portions. The front center portion has a front center portion thickness greater than a back center portion thickness. Each of the front side portions has a front side portion thickness being less than a back side portion thickness of adjacent one of the back side portions. Method of manufacturing the bumper system is provided.Type: ApplicationFiled: July 31, 2019Publication date: November 21, 2019Inventors: Edward Karl Steinebach, Jeremiah John Brady, Jeffrey Jay Mellis, Richard Lee Winfree, Mark Justin Jones, Darren Andrew Womack
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Patent number: 10407011Abstract: A bumper system including a bumper beam being cast from metal having a front panel and a back panel, extending between a first bumper beam end and a second bumper beam end. A plurality of reinforcing ribs integrally cast with the bumper beam extends between the front panel and the back panel defining a non-uniform cross-sectional profile along a portion of the bumper beam. The front panel includes a front center portion disposed between a pair of front side portions. The back panel includes a back center portion disposed between a pair of back side portions. The front center portion has a front center portion thickness greater than a back center portion thickness. Each of the front side portions has a front side portion thickness being less than a back side portion thickness of adjacent one of the back side portions. Method of manufacturing the bumper system is provided.Type: GrantFiled: October 14, 2017Date of Patent: September 10, 2019Assignee: MAGNA INTERNATIONAL INC.Inventors: Edward Karl Steinebach, Jeremiah John Brady, Jeffrey Jay Mellis, Richard Lee Winfree, Mark Justin Jones, Darren Andrew Womack
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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: 10252686Abstract: A longitudinally extending extruded aluminum bumper is constructed and used in a bumper assembly to protect a vehicle from impact. The bumper includes a three wall design, formed by an integrally formed top wall and a bottom wall interconnected by a front vertically extending wall. The top and bottom walls have open ends that are spaced relative to one another to form a longitudinally extending, open-ended channel therebetween. Upwardly extending and downwardly extending flanges are integrally formed with front vertically extending wall and the top and bottom walls of the bumper. The extruded bumper can be attached directly to an end of a vehicle. Impact absorption devices can also be inserted into the longitudinally extending channel of the bumper and abut against the front vertical wall. Welds can be provided in a non-planar manner to connect the impact absorption devices to the bumper.Type: GrantFiled: July 30, 2015Date of Patent: April 9, 2019Assignee: MAGNA INTERNATIONAL INC.Inventors: Thomas James Freundl, Jeffery Jay Mellis
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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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Publication number: 20180037179Abstract: A bumper system including a bumper beam being cast from metal having a front panel and a back panel, extending between a first bumper beam end and a second bumper beam end. A plurality of reinforcing ribs integrally cast with the bumper beam extends between the front panel and the back panel defining a non-uniform cross-sectional profile along a portion of the bumper beam. The front panel includes a front center portion disposed between a pair of front side portions. The back panel includes a back center portion disposed between a pair of back side portions. The front center portion has a front center portion thickness greater than a back center portion thickness. Each of the front side portions has a front side portion thickness being less than a back side portion thickness of adjacent one of the back side portions. Method of manufacturing the bumper system is provided.Type: ApplicationFiled: October 14, 2017Publication date: February 8, 2018Inventors: Edward Karl Steinebach, Jeremiah John Brady, Jeffrey Jay Mellis, Richard Lee Winfree, Mark Justin Jones, Darren Andrew Womack
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Publication number: 20170166148Abstract: A longitudinally extending extruded aluminum bumper is constructed and used in a bumper assembly to protect a vehicle from impact. The bumper includes a three wall design, formed by an integrally formed top wall and a bottom wall interconnected by a front vertically extending wall. The top and bottom walls have open ends that are spaced relative to one another to form a longitudinally extending, open-ended channel therebetween. Upwardly extending and downwardly extending flanges are integrally formed with front vertically extending wall and the top and bottom walls of the bumper. The extruded bumper can be attached directly to an end of a vehicle. Impact absorption devices can also be inserted into the longitudinally extending channel of the bumper and abut against the front vertical wall. Welds can be provided in a non-planar manner to connect the impact absorption devices to the bumper.Type: ApplicationFiled: July 30, 2015Publication date: June 15, 2017Inventors: Thomas James FREUNDL, Jeffery Jay MELLIS
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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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Patent number: 9073403Abstract: A hybrid torsion beam axle assembly is provided, which includes a steel torsion beam. An end cap is fastened to an end portion of the steel torsion beam, and a cast trailing arm is cast about the end portion of the steel torsion beam including the end cap. In this way, the cast trailing arm is positively and rigidly secured to the steel torsion beam.Type: GrantFiled: June 26, 2013Date of Patent: July 7, 2015Assignee: Magna International Inc.Inventors: Mark F. Werner, Timothy W. Skszek, Frank A. Horton, Warren Young, Seetarama S. Kotagiri, Gregory P. Kiselis, DeWayne Dale Egle, Gianfranco Gabbianelli, Jeffrey Jay Mellis, Erryn Leigh Ashmore, Daniel Sulisz, Pascal P. Charest, Eric deNijs, Ying Zhang, Ryan R. Warpup, Dalip K. Matharoo
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Patent number: 8919834Abstract: A bumper assembly includes a bumper beam having a bumper beam surface extending along a bumper plane X and a crash box including a crash box surface extending along a crash box plane Y. One of the bumper beam and the crash box includes an alignment joint to mate the bumper beam and the crash box and dispose the surfaces in abutting and aligned relationship relative to one another for establishing a linear load path extending linearly along the planes X, Y. A method of assembling a bumper assembly includes the steps of mating the bumper beam and the crash box about the alignment joint and connecting the bumper beam and the crash box together along the alignment joint. The step of connecting the bumper beam and the crash box includes friction stir welding the bumper box and the crash box together along the alignment joint.Type: GrantFiled: June 20, 2012Date of Patent: December 30, 2014Assignee: Magna International Inc.Inventors: Thomas James Freundl, Jeffery Jay Mellis
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Publication number: 20130285343Abstract: A hybrid torsion beam axle assembly is provided, which includes a steel torsion beam. An end cap is fastened to an end portion of the steel torsion beam, and a cast trailing arm is cast about the end portion of the steel torsion beam including the end cap. In this way, the cast trailing arm is positively and rigidly secured to the steel torsion beam.Type: ApplicationFiled: June 26, 2013Publication date: October 31, 2013Inventors: Mark F. Werner, Timothy W. Skszek, Frank A. Horton, Warren Young, Seetarama S. Kotagiri, Gregory P. Kiselis, DeWayne Dale Egle, Gianfranco Gabbianelli, Jeffrey Jay Mellis, Erryn Leigh Langlois, Daniel Sulisz, Pascal P. Charest, Eric deNijs, Ying Zhang, Ryan R. Warpup, Dalip K. Matharoo
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Patent number: 8496258Abstract: A hybrid torsion beam axle assembly is provided, which includes a steel torsion beam. An end cap is fastened to an end portion of the steel torsion beam, and a cast trailing arm is cast about the end portion of the steel torsion beam including the end cap. In this way, the cast trailing arm is positively and rigidly secured to the steel torsion beam.Type: GrantFiled: October 26, 2010Date of Patent: July 30, 2013Assignee: Magna International Inc.Inventors: Mark F. Werner, Timothy W. Skszek, Frank A. Horton, Warren Young, Seetarama S. Kotagiri, Gregory P. Kiselis, DeWayne Dale Egle, Gianfranco Gabbianelli, Jeffrey Jay Mellis, Erryn Leigh Langlois, Daniel Sulisz, Pascal P. Charest, Eric deNijs, Ying Zhang, Ryan R. Warpup, Dalip K. Matharoo
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Publication number: 20130001964Abstract: A bumper assembly includes a bumper beam having a bumper beam surface extending along a bumper plane X and a crash box including a crash box surface extending along a crash box plane Y. One of the bumper beam and the crash box includes an alignment joint to mate the bumper beam and the crash box and dispose the surfaces in abutting and aligned relationship relative to one another for establishing a linear load path extending linearly along the planes X, Y. A method of assembling a bumper assembly includes the steps of mating the bumper beam and the crash box about the alignment joint and connecting the bumper beam and the crash box together along the alignment joint. The step of connecting the bumper beam and the crash box includes friction stir welding the bumper box and the crash box together along the alignment joint.Type: ApplicationFiled: June 20, 2012Publication date: January 3, 2013Inventors: Thomas James Freundl, Jeffery Jay Mellis
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Patent number: 8061034Abstract: A method for forming a bumper beam includes providing an elongated piece of sheet metal having opposing end portions and an intermediate portion, bending the end portions with respect to the intermediate portion until the end portions are substantially perpendicular to the intermediate portion, bending a central section of the intermediate portion to form a protruding bulge in the intermediate portion after the bending the end portions, and bending side sections of the intermediate portion to move ends of the end portions adjacent to one another and adjacent to the protruding bulge after the bending the central section to from the bumper beam. The end portions form front walls of the bumper beam, the protruding bulge forms inner side walls and a web portion of the bumper beam, and the side sections form outer side walls and rear walls of the bumper beam.Type: GrantFiled: November 22, 2005Date of Patent: November 22, 2011Assignee: Magna International Inc.Inventor: Jeffery Jay Mellis
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Publication number: 20110068619Abstract: A hybrid torsion beam axle assembly is provided, which includes a steel torsion beam. An end cap is fastened to an end portion of the steel torsion beam, and a cast trailing arm is cast about the end portion of the steel torsion beam including the end cap. In this way, the cast trailing arm is positively and rigidly secured to the steel torsion beam.Type: ApplicationFiled: October 26, 2010Publication date: March 24, 2011Inventors: Mark F. WERNER, Timothy W. Skszek, Frank A. Horton, Warren Young, Seetarama S. Kotagiri, Gregory P. Kiselis, DeWayne Dale Egle, Gianfranco Gabbianelli, Jeffrey Jay Mellis, Erryn Leigh Langlois, Daniel Sulisz, Pascal P. Charest, Eric deNijs, Ying Zhang, Ryan R. Warpup, Dalip K. Matharoo
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Patent number: 7837230Abstract: A hybrid component for lightweight, structural uses, including a steel member formed of a high strength steel; and a cast coupling member cast on a portion of the steel member by casting-in-place a semi-solid aluminum about the portion of the steel member, thereby positively and rigidly securing the coupling member to the steel member. A method of forming a hybrid component for lightweight, structural uses, including: forming a steel member formed of a high strength steel into a predetermined configuration; and casting a coupling member on a portion of the steel member by casting-in-place a semi-solid aluminum about the portion of the steel member, thereby positively and rigidly securing the coupling member to the steel member.Type: GrantFiled: October 20, 2004Date of Patent: November 23, 2010Assignee: Magna International Inc.Inventors: Jeffrey Jay Mellis, Frank Gabbianelli, Erryn Leigh Langlois, Daniel Sulisz, Mark F. Werner, Timothy W. Skszek, Frank A. Horton, Warren Young, Seetarama S. Kotagiri, P. Gregory Kiselis, Dewayne Dale Egle
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Patent number: 7665777Abstract: A bumper beam for mounting to a frame assembly of a motor vehicle at one end of the motor vehicle includes opposing end portions adapted to be mounted to the frame assembly of the motor vehicle and a centrally disposed intermediate portion extending between the end portions. The end portions and the intermediate portion define an upper wall, a lower wall, and a central wall between the upper and lower walls. The upper and lower walls each have an elongated arcuate flange that extends from a free end of a respective upper and lower wall along a length of the bumper beam. The arcuate flange of each of the upper and lower walls defines an outwardly facing concave surface and an inwardly facing convex surface.Type: GrantFiled: June 30, 2005Date of Patent: February 23, 2010Assignee: Magna International Inc.Inventors: Jeffery Jay Mellis, Gianfranco Gabbianelli, Erryn Leigh Langlois, Mark A. Kessen
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Publication number: 20090064502Abstract: A method for forming a bumper beam includes providing an elongated piece of sheet metal having opposing end portions and an intermediate portion, bending the end portions with respect to the intermediate portion until the end portions are substantially perpendicular to the intermediate portion, bending a central section of the intermediate portion to form a protruding bulge in the intermediate portion after the bending the end portions, and bending side sections of the intermediate portion to move ends of the end portions adjacent to one another and adjacent to the protruding bulge after the bending the central section to from the bumper beam. The end portions form front walls of the bumper beam, the protruding bulge forms inner side walls and a web portion of the bumper beam, and the side sections form outer side walls and rear walls of the bumper beam.Type: ApplicationFiled: November 22, 2005Publication date: March 12, 2009Inventor: Jeffery Jay Mellis