Patents by Inventor Julio Malpica
Julio Malpica 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: 20230211401Abstract: Systems and methods are described for roll-forming metal substrates. The metal substrates are subjected to induction heating during the roll-forming process by exposure to time-varying magnetic fields, such as by exposure to a rotating permanent magnet, or exposure to laser radiation from a laser source. Heating of the metal substrates allows improved formability or plasticity of the substrate in order to reduce or eliminate damage to the substrate during roll-forming to low bending radius to thickness ratios. Heating of the high-strength metal substrates can also function to temper the substrates and/or improve surface corrosion resistance and form high-strength end products with desirable properties.Type: ApplicationFiled: July 21, 2021Publication date: July 6, 2023Applicant: Novelis Inc.Inventors: Julio Malpica, Rajeev G. Kamat, Anna E. Janoff, Rajasekhar Talla, Brian Matthew Walczak, Debdutta Roy, David Anthony Gaensbauer, John Min Ho, Cullen Pearson, Adolfo Rais, Carolyn Grace Kidwell, Natasha Iyer, Julie Richard, David Leyvraz, Aude Celine Despois, Stefan Felix Kempa
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Publication number: 20230166313Abstract: The invention relates to a system for making a metal product, comprising —a lubrication source (225) for applying a first lubricant (235) on a punch side of a sheet metal blank (205); —a controllable current source (250) for applying different amounts of current; and —a punch (215) and a die (220) for drawing the sheet metal blank (205) into a metal product, wherein the controllable current source (250) is electrically coupled to one or more of the punch (215), the die (220), or a contact point for applying current through the first lubricant (235) while the sheet metal blank (205) is drawn by the punch (215) and the die (220) into the metal product and while the metal product is being ejected from the punch (215). The application further relates to a method for making a metal product with a such system.Type: ApplicationFiled: March 22, 2021Publication date: June 1, 2023Applicant: Novelis Inc.Inventors: Winfried Wilhelm Kiefer, Julio Malpica, Carlos Nobrega, Jaesuk Park, Courtney Timms
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Patent number: 11649529Abstract: Disclosed are aluminum alloy products and methods of making and processing such products. Thus, disclosed are aluminum alloy products exhibiting controllable surface properties, including excellent bond durability, low contact resistance, and corrosion resistance. Aluminum alloy products described herein include a migrant element, a subsurface portion having a concentration of the migrant element, and a bulk portion having a concentration of the migrant element. The aluminum alloy product comprises an enrichment ratio of 4.0 or less, wherein the enrichment ratio is a ratio of the migrant element concentration in the subsurface portion to the concentration in the bulk portion. Additionally, the aluminum alloy products surface and/or subsurface can contain phosphorus (e.g., elemental phosphorus or oxidized phosphorus). The phosphorus containing surface provides reduced electronic stress on an electrode tip of a resistance spot welding apparatus, and an extended service lifetime (e.g.Type: GrantFiled: October 23, 2018Date of Patent: May 16, 2023Assignee: NOVELIS INC.Inventors: Liangliang Li, Theresa Elizabeth MacFarlane, Sazol Kumar Das, Peter Lloyd Redmond, Changook Son, Dewei Zhu, Yudie Yuan, Luis Fanor Vega, Milan Felberbaum, Julio Malpica, Brian Paradis, Alp Manavbasi, Dechao Lin
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Patent number: 11235369Abstract: A draw press die assembly includes an upper die, a lower die positioned beneath the upper die, a blankholder for supporting an associated workpiece, and a blankholder drive mechanism connected with at least one of the upper die and the blankholder. The blankholder drive mechanism is configured to provide a pulsating movement of the blankholder with respect to the upper die.Type: GrantFiled: September 14, 2018Date of Patent: February 1, 2022Assignee: HONDA MOTOR CO., LTD.Inventors: Dennis O'Connor, Julio Malpica, Hideo Yazaki
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Patent number: 10508328Abstract: Systems and methods of hot forming a metal blank include receiving the metal blank at a heater and positioning the blank adjacent a magnetic rotor of the heater. The systems and methods also include heating the metal blank through the magnetic rotor by rotating the magnetic rotor. Rotating the magnetic rotor induces a magnetic field into the metal blank such that the metal blank is heated.Type: GrantFiled: September 27, 2017Date of Patent: December 17, 2019Assignee: NOVELIS INC.Inventors: Julio Malpica, Cedric Wu, Rahul Vilas Kulkarni, Rodger Brown, Duane E. Bendzinski
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Publication number: 20190193185Abstract: Disclosed are aluminum alloy products and methods of making and processing such products. Thus, disclosed are aluminum alloy products exhibiting controllable surface properties, including excellent bond durability, low contact resistance, and corrosion resistance. Aluminum alloy products described herein include a migrant element, a subsurface portion having a concentration of the migrant element, and a bulk portion having a concentration of the migrant element. The aluminum alloy product comprises an enrichment ratio of 4.0 or less, wherein the enrichment ratio is a ratio of the migrant element concentration in the subsurface portion to the concentration in the bulk portion. Additionally, the aluminum alloy products surface and/or subsurface can contain phosphorus (e.g., elemental phosphorus or oxidized phosphorus). The phosphorus containing surface provides reduced electronic stress on an electrode tip of a resistance spot welding apparatus, and an extended service lifetime (e.g.Type: ApplicationFiled: October 23, 2018Publication date: June 27, 2019Applicant: Novelis Inc.Inventors: Liangliang Li, Theresa Elizabeth MacFarlane, Sazol Kumar Das, Peter Lloyd Redmond, ChangOok Son, Dewei Zhu, Yudie Yuan, Luis Fanor Vega, Milan Felberbaum, Julio Malpica, Brian Paradis, Alp Manavbasi, Dechao Lin
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Publication number: 20190047075Abstract: Disclosed are welds formed from improved resistance spot welding, as well as methods of improved resistance spot welding. Resistance spot welding includes positioning a magnet carrier having a plurality of electromagnets on at least one electrode of two electrodes. The method includes positioning a first metal sheet and a second metal sheet between the two electrodes where at least one of the first metal sheet or the second metal sheet includes an aluminum alloy. The method includes positioning the forming a weld nugget by applying a magnetic field from the plurality of electromagnets through the weld while applying a current through the electrodes to stir a portion of the first metal sheet and the second metal sheet forming a weld nugget and adjusting the magnetic field to control at least one characteristic of the weld nugget. Forming the weld nugget joins the first metal sheet with the second metal sheet.Type: ApplicationFiled: August 13, 2018Publication date: February 14, 2019Applicant: Novelis Inc.Inventors: Courtney Timms, Brian Paradis, Louis Mitchell Nazro, Julio Malpica, Rainer Kossak, Samuel Robert Wagstaff, Xiao Chai, Patrick Lester, Dechao Lin
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Publication number: 20190015888Abstract: A draw press die assembly includes an upper die, a lower die positioned beneath the upper die, a blankholder for supporting an associated workpiece, and a blankholder drive mechanism connected with at least one of the upper die and the blankholder. The blankholder drive mechanism is configured to provide a pulsating movement of the blankholder with respect to the upper die.Type: ApplicationFiled: September 14, 2018Publication date: January 17, 2019Inventors: Dennis O'Connor, Julio Malpica, Hideo Yazaki
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Patent number: 10105742Abstract: A draw press die assembly includes an upper die, a lower die positioned beneath the upper die, a blankholder for supporting an associated workpiece, and a blankholder drive mechanism connected with at least one of the upper die and the blankholder. The blankholder drive mechanism is configured to provide a pulsating movement of the blankholder with respect to the upper die.Type: GrantFiled: December 9, 2014Date of Patent: October 23, 2018Assignee: Honda Motor Co., Ltd.Inventors: Dennis O'Connor, Julio Malpica, Hideo Yazaki
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Publication number: 20180111217Abstract: Disclosed are welds formed from improved resistance spot welding. Resistance spot welding includes positioning a first metal sheet and a second metal sheet between two electrodes, contacting the two electrodes together on to opposing surfaces of the first metal sheet and the second metal sheet, and applying at least a minimum current to the first metal sheet and the second metal sheet through the two electrodes to form a weld having a minimum weld size to join the first metal sheet with the second metal sheet. At least one of the first metal sheet and the second metal sheet is a fusion alloy where the composition of at least one outer layer of the sheet is different from the composition of the core of the sheet.Type: ApplicationFiled: October 20, 2017Publication date: April 26, 2018Applicant: NOVELIS INC.Inventors: Xiao Chai, Julio Malpica, Hany Ahmed, Cyrille Bezencon, Corrado Bassi, Jörg Simon
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Publication number: 20180085810Abstract: Systems and methods of hot forming a metal blank include receiving the metal blank at a heater and positioning the blank adjacent a magnetic rotor of the heater. The systems and methods also include heating the metal blank through the magnetic rotor by rotating the magnetic rotor. Rotating the magnetic rotor induces a magnetic field into the metal blank such that the metal blank is heated.Type: ApplicationFiled: September 27, 2017Publication date: March 29, 2018Applicant: Novelis Inc.Inventors: Julio Malpica, Cedric Wu, Rahul Vilas Kulkarni, Rodger Brown, Duane E. Bendzinski
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Publication number: 20170232547Abstract: Welding techniques, including, for example, resistance spot welding, can be used to join or weld two or more metal sheets together. A clamping force and an electric current can be applied to two or more sheets to create localized melting that combines the material of the two sheets. Applying a clamping force and a cooling current can include gradually decreasing the amount of the electric current applied to the weld while applying the forging force. By adjusting the amount of the electric current applied to the weld can allow the weld to cool gradually, which may reduce thermal stresses and allow the forging force to close cracks, pores, or otherwise be used to remove or prevent defects formed in the weld.Type: ApplicationFiled: February 13, 2017Publication date: August 17, 2017Applicant: Novelis Inc.Inventors: XIAO CHAI, JULIO MALPICA, RAHUL KULKARNI
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Publication number: 20160158823Abstract: A draw press die assembly includes an upper die, a lower die positioned beneath the upper die, a blankholder for supporting an associated workpiece, and a blankholder drive mechanism connected with at least one of the upper die and the blankholder. The blankholder drive mechanism is configured to provide a pulsating movement of the blankholder with respect to the upper die.Type: ApplicationFiled: December 9, 2014Publication date: June 9, 2016Inventors: Dennis O'Connor, Julio Malpica, Hideo Yazaki
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Patent number: 8151427Abstract: A method and device is provided for measuring springback of a vehicle panel within a deformation press. This avoids the need for removing the panel from the press and fabricating a dedicated measuring fixture. A trim die in the deformation press is retrofit to perform an additional function, namely securing a deformed panel in a position such that a measurement of the panel can be made. The trim die is retrofit by modifying existing apertures and adding additional aperture(s) in required positions. In the process, after bending the panel into the press and, using the trim die, undesired material is trimmed from the deformed panel. The panel is raised and at least three fixture posts are placed in apertures in the trim die. The panel rests on the posts with one post securing the panel in either one, two or three directions. The panel is then scanned or otherwise measured to determine springback in the panel.Type: GrantFiled: March 31, 2009Date of Patent: April 10, 2012Assignee: Honda Motor Co., Ltd.Inventors: Tarik Yousef, Richard N. Carlisle, Corey Clemans, Jonathan M. Varner, Julio Malpica