Patents by Inventor Kevin Michael Gatenby
Kevin Michael Gatenby 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: 11933553Abstract: An aluminum alloy fin stock material comprising about 0.9-1.2 wt. % Si, 0.3-0.5 wt. % Fe, 0.20-0.40 wt. % Cu, 1.0-1.5 wt. % Mn, 0-0.1% Mg and 0.0-3.0% Zn, with remainder Al and impurities at ?0.15 wt. %. The aluminum alloy fin stock material is produced in a form of a sheet by a process comprising the steps of direct chill casting an ingot, hot rolling the ingot after the direct chill casting, cold rolling the aluminum alloy to an intermediate thickness, inter-annealing the aluminum alloy cold rolled to an intermediate thickness at a temperature between 200 and 400° C., and cold rolling the material after inter-annealing to achieve % cold work (% CW) of 20 to 40%. The aluminum alloy fin stock material possesses an improved combination of one or more of pre- and/or post-brazes strength, conductivity, sag resistance and corrosion potential. It is useful for fabrication of heat exchanger fins.Type: GrantFiled: March 28, 2022Date of Patent: March 19, 2024Assignees: NOVELIS INC., DENSO CORPORATIONInventors: Kevin Michael Gatenby, Hany Ahmed, Andrew D. Howells, Jyothi Kadali, Derek Aluia, John Michael Baciak, III
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Publication number: 20220221236Abstract: An aluminum alloy fin stock material comprising about 0.9-1.2 wt. % Si, 0.3-0.5 wt. % Fe, 0.20-0.40 wt. % Cu, 1.0-1.5 wt. % Mn, 0-0.1% Mg and 0.0-3.0% Zn, with remainder Al and impurities at ?0.15 wt. %. The aluminum alloy fin stock material is produced in a form of a sheet by a process comprising the steps of direct chill casting an ingot, hot rolling the ingot after the direct chill casting, cold rolling the aluminum alloy to an intermediate thickness, inter-annealing the aluminum alloy cold rolled to an intermediate thickness at a temperature between 200 and 400° C., and cold rolling the material after inter-annealing to achieve % cold work (% CW) of 20 to 40%. The aluminum alloy fin stock material possesses an improved combination of one or more of pre- and/or post-brazes strength, conductivity, sag resistance and corrosion potential. It is useful for fabrication of heat exchanger fins.Type: ApplicationFiled: March 28, 2022Publication date: July 14, 2022Applicants: NOVELIS INC., Denso CorporationInventors: Kevin Michael Gatenby, Hany Ahmed, Andrew D. Howells, Jyothi Kadali, Derek Aluia, John Michael Baciak, III
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Patent number: 10889882Abstract: Provided herein are new aluminum alloy materials which are useful in replacing copper in a heat exchanger. The aluminum alloy materials are also useful in manufacturing components of heating, ventilating, air-conditioning, and refrigeration (HVAC&R) systems for indoor and outdoor units. The alloys are well-suited for tubing in a heat exchanger. The alloys display high strength and good corrosion resistance. Also provided herein are methods for making the aluminum alloy materials.Type: GrantFiled: March 3, 2017Date of Patent: January 12, 2021Assignee: Novelis Inc.Inventors: Jyothi Kadali, Eider Alberto Simielli, Kevin Michael Gatenby
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Publication number: 20170342536Abstract: Provided herein are new aluminum alloy materials which are useful in replacing copper in a heat exchanger. The aluminum alloy materials are also useful in manufacturing components of heating, ventilating, air-conditioning, and refrigeration (HVAC&R) systems for indoor and outdoor units. The alloys are well-suited for tubing in a heat exchanger. The alloys display high strength and good corrosion resistance. Also provided herein are methods for making the aluminum alloy materials.Type: ApplicationFiled: March 3, 2017Publication date: November 30, 2017Applicant: Novelis Inc.Inventors: Jyothi Kadali, Eider Alberto Simielli, Kevin Michael Gatenby
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Patent number: 9719156Abstract: The present invention relates to an aluminum alloy product for use as a finstock material within brazed heat exchangers and, more particularly, to a finstock material having high strength and conductivity after brazing. The invention is an aluminum alloy finstock comprising the following composition in weight %: Fe ?0.8-1.25; Si ?0.8-1.25; Mn 0.70-1.50; Cu 0.05-0.50; Zn up to 2.5; other elements less than or equal to 0.05 each and less than or equal to 0.15 in total; and balance aluminum. The invention also relates to a method of making the finstock material.Type: GrantFiled: December 7, 2012Date of Patent: August 1, 2017Assignee: Novelis Inc.Inventors: Andrew D. Howells, Kevin Michael Gatenby, Pierre Henri Marois, Thomas L. Davisson, Fred Perdriset
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Patent number: 9545777Abstract: This application discloses a corrosion-resistant brazing sheet package for use in manufacturing tubing. The brazing sheet package includes a core layer of aluminum-containing alloy comprising from 0.1 wt % to 0.2 wt % of titanium. The core layer has a first side and a second side. The first side of the core layer is adjacent to a first cladding layer to form a first interface. The second side of the core layer is adjacent to a second cladding layer to form a second interface. The first cladding layer and the second cladding layer each include from 2.5 wt % to 4.0 wt % of zinc.Type: GrantFiled: March 12, 2014Date of Patent: January 17, 2017Assignee: Novelis Inc.Inventors: Pierre Henri Marois, Kevin Michael Gatenby, Andrew D. Howells
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Patent number: 9546829Abstract: The present invention provides a new aluminum alloy material which may be used for a core alloy of a corrosion-resistant brazing sheet. This core alloy displays with high strength, and good corrosion resistance for use in heat exchangers. This aluminum alloy material was made by direct chill (DC) casting. The present inventions also provides corrosion-resistant brazing sheet packages including the aluminum alloy material as a core and one or more cladding layers.Type: GrantFiled: March 12, 2014Date of Patent: January 17, 2017Assignee: Novelis Inc.Inventors: Andrew D. Howells, Hany Ahmed, Kevin Michael Gatenby, Jyothi Kadali, Pierre Henri Marois
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Publication number: 20160355915Abstract: Described herein are novel aluminum-containing alloys. The alloys are highly formable, exhibit high strength and corrosion resistance, and are recyclable. The alloys can be used in electronics, transportation, industrial, and automotive applications, just to name a few. Also described herein are methods for producing metal ingots and products obtained by the methods.Type: ApplicationFiled: June 3, 2016Publication date: December 8, 2016Applicant: Novelis Inc.Inventors: Jyothi Kadali, Kevin Michael Gatenby, Daehoon Kang, Sazol Kumar Das
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Publication number: 20160195346Abstract: The present invention provides an aluminum alloy fm stock alloy material with higher strength, and improved sag resistance for use in heat exchangers. This aluminum alloy fm stock alloy material was made by direct chill (DC) casting.Type: ApplicationFiled: August 8, 2014Publication date: July 7, 2016Applicant: NOVELIS INC.Inventors: Andrew D. Howells, Kevin Michael Gatenby
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Publication number: 20160040947Abstract: An aluminum alloy fin stock material comprising about 0.9-1.2 wt. % Si, 0.3-0.5 wt. % Fe, 0.20-0.40 wt. % Cu, 1.0-1.5 wt. % Mn, 0-0.1% Mg and 0.0-3.0% Zn, with remainder Al and impurities at ?0.15 wt. %. The aluminum alloy fin stock material is produced in a form of a sheet by a process comprising the steps of direct chill casting an ingot, hot rolling the ingot after the direct chill casting, cold rolling the aluminum alloy to an intermediate thickness, inter-annealing the aluminum alloy cold rolled to an intermediate thickness at a temperature between 200 and 400° C., and cold rolling the material after inter-annealing to achieve % cold work (% CW) of 20 to 40%. The aluminum alloy fin stock material possesses an improved combination of one or more of pre- and/or post-brazes strength, conductivity, sag resistance and corrosion potential. It is useful for fabrication of heat exchanger fins.Type: ApplicationFiled: August 3, 2015Publication date: February 11, 2016Applicant: NOVELIS INC.Inventors: Kevin Michael Gatenby, Hany Ahmed, Andrew D. Howells, Jyothi Kadali
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Publication number: 20150041027Abstract: The present invention provides an aluminum alloy fin stock material with higher strength, and improved sag resistance for use in heat exchangers, such as automotive heat exchangers. The aluminum alloy fin stock material is produced from an aluminum alloy comprising about 0.8-1.4 wt % Si, 0.4-0.8 wt % Fe, 0.05-0.4 wt % Cu, 1.2-1.7 wt % Mn and 1.20-2.3 wt % Zn, with the remainder as Al. The aluminum alloy fin stock material is made by a process comprising direct chill casting the aluminum alloy into an ingot, preheating the ingot, hot rolling the preheated ingot, cold rolling the ingot and inter-annealing at a temperature of 275-400° C. After inter-annealing, the aluminum alloy fin stock material is a cold rolled in a final cold rolling step to achieve % cold work (% CW) of 20-35%.Type: ApplicationFiled: August 7, 2014Publication date: February 12, 2015Applicants: Novelis Inc., Denso CorporationInventors: Andrew D. Howells, Kevin Michael Gatenby, Hany Ahmed, Jyothi Kadali, Derek William Aluia, John Michael Baciak, III
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Publication number: 20140272461Abstract: This application discloses a corrosion-resistant brazing sheet package for use in manufacturing tubing. The brazing sheet package includes a core layer of aluminum-containing alloy comprising from 0.1 wt % to 0.2 wt % of titanium. The core layer has a first side and a second side. The first side of the core layer is adjacent to a first cladding layer to form a first interface. The second side of the core layer is adjacent to a second cladding layer to form a second interface. The first cladding layer and the second cladding layer each include from 2.5 wt % to 4.0 wt % of zinc.Type: ApplicationFiled: March 12, 2014Publication date: September 18, 2014Applicant: NOVELIS INC.Inventors: PIERRE HENRI MAROIS, KEVIN MICHAEL GATENBY, ANDREW D. HOWELLS
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Publication number: 20140272460Abstract: The present invention provides a new aluminum alloy material which may be used for a core alloy of a corrosion-resistant brazing sheet. This core alloy displays with high strength, and good corrosion resistance for use in heat exchangers. This aluminum alloy material was made by direct chill (DC) casting. The present inventions also provides corrosion-resistant brazing sheet packages including the aluminum alloy material as a core and one or more cladding layers.Type: ApplicationFiled: March 12, 2014Publication date: September 18, 2014Applicant: NOVELIS INC.Inventors: ANDREW D. HOWELLS, HANY AHMED, KEVIN MICHAEL GATENBY, JYOTHI KADALI, PIERRE HENRI MAROIS
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Patent number: 8813826Abstract: Embodiments of the invention relate to a method and apparatus for continuously casting a metal slab. The method involves continuously introducing molten metal into an inlet of a casting cavity defined between advancing casting surfaces, cooling the metal in the cavity to form a metal slab, and discharging the slab from the cavity through an outlet. The casting surfaces have an ability to remove heat from the metal but this ability is reduced, thus reducing heat flux, for at least one of the casting surfaces in a region of the cavity spaced from both the inlet and the outlet and extending transversely to the casting direction. This reduced ability to remove heat is relative to such ability of the casting surface in immediately adjacent upstream and downstream regions of the cavity. The apparatus may be a twin belt caster or other form of continuous caster modified to perform the method.Type: GrantFiled: December 13, 2013Date of Patent: August 26, 2014Assignee: Novelis Inc.Inventors: Kevin Michael Gatenby, Edwin Stanley Luce
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Publication number: 20140096929Abstract: Embodiments of the invention relate to a method and apparatus for continuously casting a metal slab. The method involves continuously introducing molten metal into an inlet of a casting cavity defined between advancing casting surfaces, cooling the metal in the cavity to form a metal slab, and discharging the slab from the cavity through an outlet. The casting surfaces have an ability to remove heat from the metal but this ability is reduced, thus reducing heat flux, for at least one of the casting surfaces in a region of the cavity spaced from both the inlet and the outlet and extending transversely to the casting direction. This reduced ability to remove heat is relative to such ability of the casting surface in immediately adjacent upstream and downstream regions of the cavity. The apparatus may be a twin belt caster or other form of continuous caster modified to perform the method.Type: ApplicationFiled: December 13, 2013Publication date: April 10, 2014Applicant: Novelis Inc.Inventors: Kevin Michael Gatenby, Edwin Stanley Luce
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Patent number: 8662145Abstract: Embodiments of the invention relate to a method and apparatus for continuously casting a metal slab. The method involves continuously introducing molten metal into an inlet of a casting cavity defined between advancing casting surfaces, cooling the metal in the cavity to form a metal slab, and discharging the slab from the cavity through an outlet. The casting surfaces have an ability to remove heat from the metal but this ability is reduced, thus reducing heat flux, for at least one of the casting surfaces in a region of the cavity spaced from both the inlet and the outlet and extending transversely to the casting direction. This reduced ability to remove heat is relative to such ability of the casting surface in immediately adjacent upstream and downstream regions of the cavity. The apparatus may be a twin belt caster or other form of continuous caster modified to perform the method.Type: GrantFiled: February 12, 2013Date of Patent: March 4, 2014Assignee: Novelis Inc.Inventors: Kevin Michael Gatenby, Edward Stanley Luce
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Publication number: 20130248137Abstract: Embodiments of the invention relate to a method and apparatus for continuously casting a metal slab. The method involves continuously introducing molten metal into an inlet of a casting cavity defined between advancing casting surfaces, cooling the metal in the cavity to form a metal slab, and discharging the slab from the cavity through an outlet. The casting surfaces have an ability to remove heat from the metal but this ability is reduced, thus reducing heat flux, for at least one of the casting surfaces in a region of the cavity spaced from both the inlet and the outlet and extending transversely to the casting direction. This reduced ability to remove heat is relative to such ability of the casting surface in immediately adjacent upstream and downstream regions of the cavity. The apparatus may be a twin belt caster or other form of continuous caster modified to perform the method.Type: ApplicationFiled: February 12, 2013Publication date: September 26, 2013Inventors: Kevin Michael GATENBY, Edwin Stanley Luce
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Publication number: 20130156634Abstract: The present invention relates to an aluminum alloy product for use as a finstock material within brazed heat exchangers and, more particularly, to a finstock material having high strength and conductivity after brazing. The invention is an aluminum alloy finstock comprising the following composition in weight %: Fe ?0.8-1.25; Si ?0.8-1.25; Mn 0.70-1.50; Cu 0.05-0.50; Zn up to 2.5; other elements less than or equal to 0.05 each and less than or equal to 0.15 in total; and balance aluminum. The invention also relates to a method of making the finstock material.Type: ApplicationFiled: December 7, 2012Publication date: June 20, 2013Inventors: Andrew D. HOWELLS, Kevin Michael Gatenby, Pierre Henri Marois, Thomas L. Davisson, Fred Perdriset
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Patent number: 8349470Abstract: The exemplary embodiments relate to a multilayer aluminum alloy sheet material suitable for fabrication into coolant-conveying tubes, headers and the like used for heat exchangers, and to the tubes and headers, etc., fabricated from the sheet. The multi-layer metal sheet has a core layer of aluminum alloy having first and second sides. The first side has an interlayer made of a Zn-containing aluminum alloy positioned between a Zn-containing outer layer and the core layer. The alloy of the outer layer is more electronegative than the alloy of the interlayer. The alloy of the interlayer is preferably more electronegative than the alloy of the core layer. The first side clad in this way is the side intended for exposure to the coolant, and provides good resistance to corrosion and erosion.Type: GrantFiled: December 17, 2009Date of Patent: January 8, 2013Assignee: Novelis Inc.Inventors: Pierre Henri Marois, Kevin Michael Gatenby, Thomas L. Davisson, Andrew D. Howells, Ian Smith
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Patent number: 7823623Abstract: A twin-belt casting machine for casting metal strip. The machine is provided with a casting cavity which includes an upstream fixed casting region, in which the belts are in fixed convergent paths in contact with the cast slab, and an adjacent downstream portion in which the belts are adjustable between alignment with the fixed convergent paths and non-alignment therewith (being less convergent or divergent). When the adjustable portions of the paths are moved outwardly relative to the fixed convergent paths, the belts separate from the cast slab at differing predetermined points within the casting cavity. By adjusting the downstream portion of the casting cavity in this manner, the casting machine can operate at essentially constant throughput for a wide range of alloys while ensuring that the cast slab exiting the caster has a temperature within a predetermined range suitable for further rolling to produce sheet product.Type: GrantFiled: March 15, 2007Date of Patent: November 2, 2010Assignee: Novelis Inc.Inventors: John Fitzsimon, Ronald Roger Desrosiers, Willard Mark Truman Gallerneault, Kevin Michael Gatenby