Patents by Inventor Joseph R. Matecki
Joseph R. Matecki 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: 20230303179Abstract: A vehicle rocker assembly includes a sill outer and a sill inner that together define an elongated hollow interior. The vehicle rocker assembly also includes a rocker insert disposed within the elongated hollow interior. The rocker insert includes a stiffening member defining a wave-shaped structure and including at least one sheet defining a fore edge, an aft edge, a first side edge and a second side edge opposite the first side edge. Additionally, the fore edge and the aft edge are disposed at different locations along the length of the rocker insert. Moreover, a crest of the wave-shaped structure extends between the first side edge and the second side edge and is configured to carry a load path laterally between the inboard and outboard wall portions.Type: ApplicationFiled: March 27, 2023Publication date: September 28, 2023Inventors: Matthew Kuipers, Zehua Qin, Joseph R. Matecki, Bruce Walsh, Marcus Ashmore
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Patent number: 11766976Abstract: A hybrid bumper assembly for a vehicle includes a steel reinforcement beam and aluminum crush cans attached to end portions of the steel reinforcement beam. The reinforcement beam has a multi-tubular shape that is formed by a high-strength steel sheet that is roll formed to provide at least two tubular portions. A crush can has an interfacing portion that is coupled to an end portion of the reinforcement beam. The end portions of the reinforcement beam and the interfacing portion of the crush cans may be configured to attach together using a select joining technology in a manner that minimizes or eliminates bimetallic or galvanic corrosion between the reinforcement beam and the crush cans.Type: GrantFiled: February 1, 2023Date of Patent: September 26, 2023Assignee: Shape Corp.Inventor: Joseph R. Matecki
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Publication number: 20230264246Abstract: A multi-tubular beam for a vehicle, such as a vehicle structure or a bumper reinforcement, includes an elongated beam formed with a metal sheet. The metal sheet has a central section and outer sections extending along a length of the metal sheet. The outer sections are disposed in opposing directions from the outer edges of the central section to provide adjacent first and second tubular portions. The central section forms a common center wall between the adjacent first and second tubular portions. A first edge portion of the metal sheet is disposed along and in parallel alignment with the center wall. The first edge portion is attached to the center wall at a first weld joint to form the first tubular portion. The first weld joint includes a weld material that extends through a thickness of the center wall and into a thickness of the first edge portion.Type: ApplicationFiled: April 28, 2023Publication date: August 24, 2023Inventors: Douglas S. Baas, Joseph R. Matecki, Shawn R. Jasman
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Publication number: 20230182666Abstract: A hybrid bumper assembly for a vehicle includes a steel reinforcement beam and aluminum crush cans attached to end portions of the steel reinforcement beam. The reinforcement beam has a multi-tubular shape that is formed by a high-strength steel sheet that is roll formed to provide at least two tubular portions. A crush can has an interfacing portion that is coupled to an end portion of the reinforcement beam. The end portions of the reinforcement beam and the interfacing portion of the crush cans may be configured to attach together using a select joining technology in a manner that minimizes or eliminates bimetallic or galvanic corrosion between the reinforcement beam and the crush cans.Type: ApplicationFiled: February 1, 2023Publication date: June 15, 2023Inventor: Joseph R. Matecki
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Patent number: 11660950Abstract: A battery support structure for a vehicle includes a first peripheral member configured to be supported by a longitudinal section of a vehicle frame. A second peripheral member has an end surface that selectively attaches at an inside surface of the first peripheral member to enclose a corner section of a battery containment area. Prior to fixed attachment of the first and second peripheral members, a slip plane is defined between the end surface and the inside surface to adjust the second peripheral member along the first peripheral member to a predefined dimension of the battery containment area.Type: GrantFiled: March 15, 2022Date of Patent: May 30, 2023Assignee: Shape Corp.Inventors: Joseph R. Matecki, Dennis V. Rupar, James H. Dodd
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Patent number: 11660652Abstract: A multi-tubular beam for a vehicle, such as a vehicle structure or a bumper reinforcement, includes an elongated beam formed with a metal sheet. The metal sheet has a central section and outer sections extending along a length of the metal sheet. The outer sections are disposed in opposing directions from the outer edges of the central section to provide adjacent first and second tubular portions. The central section forms a common center wall between the adjacent first and second tubular portions. A first edge portion of the metal sheet is disposed along and in parallel alignment with the center wall. The first edge portion is attached to the center wall at a first weld joint to form the first tubular portion. The first weld joint includes a weld material that extends through a thickness of the center wall and into a thickness of the first edge portion.Type: GrantFiled: November 10, 2020Date of Patent: May 30, 2023Assignee: Shape Corp.Inventors: Douglas S. Baas, Joseph R. Matecki, Shawn R. Jasman
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Publication number: 20230159107Abstract: A rocker component for a vehicle includes a reinforcement beam having a metal sheet that is shaped with a plurality of elongated bends extending in parallel along a length of the reinforcement beam that together form a cross-sectional shape extending continuously along the length of the reinforcement beam. The cross-sectional shape of reinforcement beam includes a beam portion and a flange portion integrally extending from the beam portion. The beam portion has a multi-hollow shape that encloses a plurality of hollow cavities that extend longitudinally between openings at opposing ends of the reinforcement beam. The flange portion integrally extends from the beam portion and includes an edge of the metal sheet. The flange portion is configured to attach to the vehicle for supporting the rocker component along an outboard side region of the vehicle.Type: ApplicationFiled: January 23, 2023Publication date: May 25, 2023Inventors: Joseph R. Matecki, Brian Oxley, Matthew Kuipers, Cody Alger, Douglas Baas
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Publication number: 20230062947Abstract: A reinforcement beam for an automotive component is continuously formed with a metal sheet that is roll formed to have at least one tubular portion that extends along a length of the reinforcement beam. A solid state forge weld is formed between an edge of the metal sheet and an intermediate portion of the metal sheet to close a seam that extends along the tubular portion of the reinforcement beam. Prior to forming the solid state forge weld, select portions of the metal sheet are heated to a desirable welding temperature with a high frequency current delivered by electrical contacts to opposing sides of the weld seam. The desired welding temperature may burn off a galvanized coating on the metal sheet at the select portions prior to forming the solid state forge weld that is generally void of zinc inclusions.Type: ApplicationFiled: August 30, 2021Publication date: March 2, 2023Inventors: Joseph R. Matecki, Jeffrey McHenry, Scott Navarre
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Patent number: 11590911Abstract: A hybrid bumper assembly for a vehicle includes a steel reinforcement beam and aluminum crush cans attached to end portions of the steel reinforcement beam. The reinforcement beam has a multi-tubular shape that is formed by a high-strength steel sheet that is roll formed to provide at least two tubular portions. A crush can has an interfacing portion that is coupled to an end portion of the reinforcement beam. The end portions of the reinforcement beam and the interfacing portion of the crush cans may be configured to attach together using a select joining technology in a manner that minimizes or eliminates bimetallic or galvanic corrosion between the reinforcement beam and the crush cans.Type: GrantFiled: July 27, 2020Date of Patent: February 28, 2023Assignee: Shape Corp.Inventor: Joseph R. Matecki
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Patent number: 11560180Abstract: A rocker component for a vehicle includes a reinforcement beam having a metal sheet that is shaped with a plurality of elongated bends extending in parallel along a length of the reinforcement beam that together form a cross-sectional shape extending continuously along the length of the reinforcement beam. The cross-sectional shape of reinforcement beam includes a beam portion and a flange portion integrally extending from the beam portion. The beam portion has a multi-hollow shape that encloses a plurality of hollow cavities that extend longitudinally between openings at opposing ends of the reinforcement beam. The flange portion integrally extends from the beam portion and includes an edge of the metal sheet. The flange portion is configured to attach to the vehicle for supporting the rocker component along an outboard side region of the vehicle.Type: GrantFiled: April 5, 2021Date of Patent: January 24, 2023Assignee: Shape Corp.Inventors: Joseph R. Matecki, Brian Oxley, Matthew Kuipers, Cody Alger, Douglas S. Baas
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Publication number: 20230001870Abstract: A vehicle beam assembly includes a hollow tubular member configured to be formed with steel tube air forming. The tubular member includes a varied cross section along a length of the tubular member. For example, the hollow tubular member includes a center portion having a first cross-sectional shape, a pair of end portions that extend past corresponding crush cans in a direction away from the center portion, where the pair of end portions extend at an angle of 40-70 degrees, and at least one transition portion disposed between the center portion and one of the pair of end portions. A cross-sectional shape of the center portion, a cross sectional shape of one of the end portions, and a cross-sectional shape of the transition portion are all different cross-sectional shapes.Type: ApplicationFiled: July 5, 2022Publication date: January 5, 2023Inventors: Joseph R. Matecki, Jeffrey A. McHenry, Matthew Kuipers, Kannan Ramamoorthy
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Patent number: 11427144Abstract: A galvanized reinforcement beam is continuously formed by uncoiling a roll of galvanized sheet stock in a generally horizontal plane. Protrusions are formed at an upper surface of the sheet stock, which is then roll formed to form a tubular shape with the protrusions abutting a surface of the sheet stock to form venting gaps. The sheet stock is laser welded at the protrusions to continuously form a weld joint, where zinc oxide gas generated from the welding is permitted to escape an interior of the tubular shape through the venting gaps.Type: GrantFiled: November 26, 2019Date of Patent: August 30, 2022Assignee: Shape Corp.Inventors: Douglas S. Baas, Joseph R. Matecki, Shawn R. Jasman
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Publication number: 20220212720Abstract: A rocker component for a vehicle having a reinforcement beam including a metal sheet that is shaped with a plurality of elongated bends extending in parallel along a length of the reinforcement beam that together form a cross-sectional shape extending continuously along the length of the reinforcement beam. The cross-sectional shape of the reinforcement beam includes a beam portion and a flange portion integrally extending from the beam portion and includes an edge of the metal sheet. The rocker component also includes a sill panel having flanges extending longitudinally along upper and lower edges of the sill panel relative to the vehicle, the flange portion of the reinforcement beam joined to one of the flanges of the sill panel to secure the reinforcement beam to the sill panel in replacement of a separate second sill panel.Type: ApplicationFiled: March 28, 2022Publication date: July 7, 2022Inventors: Brian Oxley, Matthew Kuipers, Joseph R. Matecki, Cody Alger, Douglas S. Baas
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Publication number: 20220194201Abstract: A battery support structure for a vehicle includes a first peripheral member configured to be supported by a longitudinal section of a vehicle frame. A second peripheral member has an end surface that selectively attaches at an inside surface of the first peripheral member to enclose a corner section of a battery containment area. Prior to fixed attachment of the first and second peripheral members, a slip plane is defined between the end surface and the inside surface to adjust the second peripheral member along the first peripheral member to a predefined dimension of the battery containment area.Type: ApplicationFiled: March 15, 2022Publication date: June 23, 2022Inventors: Joseph R. Matecki, Dennis V. Rupar, James H. Dodd
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Patent number: 11273697Abstract: A battery support structure for a vehicle includes a first peripheral member configured to be supported by a longitudinal section of a vehicle frame. A second peripheral member has an end surface that selectively attaches at an inside surface of the first peripheral member to enclose a corner section of a battery containment area. Prior to fixed attachment of the first and second peripheral members, a slip plane is defined between the end surface and the inside surface to adjust the second peripheral member along the first peripheral member to a predefined dimension of the battery containment area.Type: GrantFiled: March 11, 2020Date of Patent: March 15, 2022Assignee: Shape Corp.Inventors: Joseph R. Matecki, Dennis V. Rupar, James H. Dodd
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Publication number: 20210309297Abstract: A rocker component for a vehicle includes a reinforcement beam having a metal sheet that is shaped with a plurality of elongated bends extending in parallel along a length of the reinforcement beam that together form a cross-sectional shape extending continuously along the length of the reinforcement beam. The cross-sectional shape of reinforcement beam includes a beam portion and a flange portion integrally extending from the beam portion. The beam portion has a multi-hollow shape that encloses a plurality of hollow cavities that extend longitudinally between openings at opposing ends of the reinforcement beam. The flange portion integrally extends from the beam portion and includes an edge of the metal sheet. The flange portion is configured to attach to the vehicle for supporting the rocker component along an outboard side region of the vehicle.Type: ApplicationFiled: April 5, 2021Publication date: October 7, 2021Inventors: Joseph R. Matecki, Brian Oxley, Matthew Kuipers, Cody Alger, Douglas S. Baas
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Publication number: 20210053517Abstract: A multi-tubular beam for a vehicle, such as a vehicle structure or a bumper reinforcement, includes an elongated beam formed with a metal sheet. The metal sheet has a central section and outer sections extending along a length of the metal sheet. The outer sections are disposed in opposing directions from the outer edges of the central section to provide adjacent first and second tubular portions. The central section forms a common center wall between the adjacent first and second tubular portions. A first edge portion of the metal sheet is disposed along and in parallel alignment with the center wall. The first edge portion is attached to the center wall at a first weld joint to form the first tubular portion. The first weld joint includes a weld material that extends through a thickness of the center wall and into a thickness of the first edge portion.Type: ApplicationFiled: November 10, 2020Publication date: February 25, 2021Inventors: Douglas S. Baas, Joseph R. Matecki, Shawn R. Jasman
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Publication number: 20210024022Abstract: A hybrid bumper assembly for a vehicle includes a steel reinforcement beam and aluminum crush cans attached to end portions of the steel reinforcement beam. The reinforcement beam has a multi-tubular shape that is formed by a high-strength steel sheet that is roll formed to provide at least two tubular portions. A crush can has an interfacing portion that is coupled to an end portion of the reinforcement beam. The end portions of the reinforcement beam and the interfacing portion of the crush cans may be configured to attach together using a select joining technology in a manner that minimizes or eliminates bimetallic or galvanic corrosion between the reinforcement beam and the crush cans.Type: ApplicationFiled: July 27, 2020Publication date: January 28, 2021Applicant: Shape Corp.Inventor: Joseph R. Matecki
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Publication number: 20200207221Abstract: A battery support structure for a vehicle includes a first peripheral member configured to be supported by a longitudinal section of a vehicle frame. A second peripheral member has an end surface that selectively attaches at an inside surface of the first peripheral member to enclose a corner section of a battery containment area. Prior to fixed attachment of the first and second peripheral members, a slip plane is defined between the end surface and the inside surface to adjust the second peripheral member along the first peripheral member to a predefined dimension of the battery containment area.Type: ApplicationFiled: March 11, 2020Publication date: July 2, 2020Inventors: Joseph R. Matecki, Dennis V. Rupar, James H. Dodd
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Publication number: 20200164820Abstract: A galvanized reinforcement beam is continuously formed by uncoiling a roll of galvanized sheet stock in a generally horizontal plane. Protrusions are formed at an upper surface of the sheet stock, which is then roll formed to form a tubular shape with the protrusions abutting a surface of the sheet stock to form venting gaps. The sheet stock is laser welded at the protrusions to continuously form a weld joint, where zinc oxide gas generated from the welding is permitted to escape an interior of the tubular shape through the venting gaps.Type: ApplicationFiled: November 26, 2019Publication date: May 28, 2020Inventors: Douglas S. Baas, Joseph R. Matecki, Shawn R. Jasman