Patents by Inventor Mark P. Birka
Mark P. Birka 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: 11724576Abstract: A liftgate assembly having finished show surfaces, and process of manufacturing same. The liftgate assembly includes local reinforcements that are overmolded to first reinforcements, and the first reinforcements are infrared welding to a first panel. Second and third reinforcements are also infrared welded to the first panel. To infrared weld the respective reinforcements to the first panel in predetermined locations with respect to the first panel, nesting structures are provided to hold the respective reinforcements and first panel. At least one infrared heating fixture heats various predetermined surfaces on the reinforcements and first panel, and the parts are then pressed together for joining the predetermined surfaces of the respective parts together. The process is repeated, if needed, until all of the reinforcements are infrared welded to the first panel. Outer panels are bonded to the second and third reinforcements.Type: GrantFiled: February 16, 2018Date of Patent: August 15, 2023Assignee: Magna Exteriors Inc.Inventors: Stanislav Tichy, Mark P. Birka, Riad Chaaya, Paul Hasl
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Patent number: 11628891Abstract: An automobile panel that are formed using at least partially using a pultrusion forming process. Examples of automobile panels formed using pultrusion include, but are not limited to tail gates, roofs, hatches, doors, hoods, bed liners, floor liners, bed steps, running boards, bumper covers etc. The automobile panel includes a pultruded core panel formed of a polymer resin material having continuous fibers extending across a length of the pultruded core panel, wherein the pultruded core panel has a plurality of channels extending across a surface of the pultruded core panel, wherein the channels have openings at opposing ends of the surface. Also included is an interior finish panel connected to a first side of the pultruded core panel and an exterior finished panel connected to a second side the pultruded core panel.Type: GrantFiled: January 15, 2021Date of Patent: April 18, 2023Assignee: MAGNA EXTERIORS, INC.Inventors: Mark P. Birka, Peter G. DeMarois
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Publication number: 20220347900Abstract: A three-dimensional overmolding and process for manufacturing same. The three-dimensional overmolding has a three-dimensional structure with overmolding, which gives significant performance benefits. Assembly and joining of reinforcements is done before the overmolding or in the injection molding tool. The three-dimensional overmolding meets predetermined structural requirements without requiring secondary operations and at a lower mass and cost. The structural benefits are due to the three dimensional shape in combination with the benefit of the overmolding process.Type: ApplicationFiled: June 19, 2020Publication date: November 3, 2022Applicant: Magna Exteriors Inc.Inventors: Stanislav Tichy, Riad Chaaya, Mark P. Birka, Christopher J. Kuntze, Heiner Salzmann
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Publication number: 20220348060Abstract: A liftgate having an overmolded hinge point comprising a metal reinforcement overmolded with a polymer and having a compression limiter portion molded in. The compression limiter portion including a tubular portion for receiving a fastener encapsulated during overmolding and having overmolded gusset ribs extending therefrom during the overmolding process.Type: ApplicationFiled: June 19, 2020Publication date: November 3, 2022Applicant: Magna Exteriors Inc.Inventors: Stanislav Tichy, Riad Chaaya, Mark P. Birka, Christopher J. Kuntze, Jeff Rubis, Heiner Salzmann
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Publication number: 20220339994Abstract: Metal rib overmolding joining including creating geometrical features in reinforcements for interconnecting a three-dimensional metal reinforcement to a metal base plate of an overmolding part in order to transfer load forces. Interlocked reinforcement is pre-assembled or assembled in an injection molding tool. Geometric features are positioned and joined creating a connection geometry that is overmolded. The joints created between the metal reinforcements are done without a welding process.Type: ApplicationFiled: June 19, 2020Publication date: October 27, 2022Applicant: Magna Exteriors Inc.Inventors: Stanislav Tichy, Riad Chaaya, Mark P. Birka, Christopher J. Kuntze, Heiner Salzmann
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Publication number: 20220266664Abstract: A liftgate (28) formed with a thermoplastic which is overmolded around preselected reinforcements at stress points, such as a corner area, which includes a pair of separate reinforcement plates (14,18) and wherein a 3-dimensional reinforcement plate (12) is connected between the pair of separate reinforcements (14,18). Preferably the 3-dimensional reinforcement plate is connected to three reinforcements.Type: ApplicationFiled: June 19, 2020Publication date: August 25, 2022Applicant: Magna Exteriors Inc.Inventors: Stanislav Tichy, Riad Chaaya, Mark P. Birka, Christopher J. Kuntze, Heiner Salzmann
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Patent number: 11305822Abstract: A liftgate arrangement including a thermoplastic inner panel with an outer surface and an inner surface. The liftgate arrangement further includes one or more carbon fiber sheet mold compound reinforcements connected to and extending across a portion of the outer surface of the inner panel. The one or more carbon fiber sheet mold compound reinforcements also includes a channel extending between two openings on the one or more carbon fiber sheet mold compound reinforcements. The one or more carbon fiber sheet mold compound reinforcements are used to strengthen the inner panel at desired locations.Type: GrantFiled: November 26, 2019Date of Patent: April 19, 2022Assignee: MAGNA EXTERIORS, INC.Inventors: Christopher John Kuntze, Mark P. Birka, Sinisa Andrasic, Scott Varisto, William J. J. Harney
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Publication number: 20210347235Abstract: A liftgate arrangement (10) including a thermoplastic inner panel (12) with an outer surface and an inner surface. The liftgate arrangement further includes one or more blow molded reinforcements (18, 20) connected to and extending across a portion of the outer surface of the inner panel (12). The one or more blow molded reinforcements (18, 20) also includes a hollow channel (22, 22?) extending between two openings on the one or more blow molded reinforcements. The one or more blow molded reinforcements (18, 20) are used to strengthen the inner panel at desired locations.Type: ApplicationFiled: November 6, 2019Publication date: November 11, 2021Applicant: Magna Exteriors Inc.Inventors: Christopher John Kuntze, Mark P. Birka, Scott Varisto, Stanislav Tichy, Heiner Salzmann, Sinisa Andrasic
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Publication number: 20210283999Abstract: A liftgate structure having a composite inner panel with an outside surface having a lower perimeter surface area extending across the entire width of the composite liftgate structure. Connectable to the inner panel is a composite outer panel that has an inside surface with a lower perimeter surface area extending across substantially the entire width of the liftgate structure. Between the inner panel in the outer panel is a backing curtain. The backing curtain is connected to the outside surface of the inner panel such that the backing curtain is positioned between the outer panel on the inner panel and extends substantially across both the lower perimeter surface area of the inner panel and the lower perimeter surface area of the outer panel. The backing curtain prevents broken pieces of the outer panel for moving past the backing curtain in the event of an impact on the liftgate structure.Type: ApplicationFiled: October 6, 2017Publication date: September 16, 2021Applicant: Magna Exteriors Inc.Inventors: William J.J. Harney, Keijo J. Huotari, Mark P. Birka, Heiner Salzmann, Gerard Oslzewski, Steven Grgac
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Publication number: 20210214023Abstract: An automobile panel that are formed using at least partially using a pultrusion forming process. Examples of automobile panels formed using pultrusion include, but are not limited to tail gates, roofs, hatches, doors, hoods, bed liners, floor liners, bed steps, running boards, bumper covers etc. The automobile panel includes a pultruded core panel formed of a polymer resin material having continuous fibers extending across a length of the pultruded core panel, wherein the pultruded core panel has a plurality of channels extending across a surface of the pultruded core panel, wherein the channels have openings at opposing ends of the surface. Also included is an interior finish panel connected to a first side of the pultruded core panel and an exterior finished panel connected to a second side the pultruded core panel.Type: ApplicationFiled: January 15, 2021Publication date: July 15, 2021Applicant: Magna Exteriors Inc.Inventors: Mark P. Birka, Peter G. DeMarois
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Publication number: 20210155296Abstract: A modular gate combined with multiple functions which can be easily employed with existing tailgates without any hardware or mounting modifications to existing truck beds. There is provided a modular tailgate system having a tailgate portion in combination with a plurality of functions. The modular tailgate system integrates any combinations of at least two of the plurality of features without affecting existing body sides and/or existing truck beds. Integrated features include a multi-functional gate (e.g., swing, drop, etc), storage (e.g., normal, sealed, refrigerated, heated, etc), step(s), lighting (e.g., ingress/egress, bed interior, removable, trailer hitch, parking, etc), bed extension(s), power (e.g., 12 v and/or 110 v), tie downs (e.g., ratchets, anchors, etc), sawhorse, magnet(s), table(s), bench(es), seat(s), net(s), any other predetermined desired function, etc., and combinations thereof.Type: ApplicationFiled: February 24, 2020Publication date: May 27, 2021Applicant: Magna Exteriors Inc.Inventors: Anthony J. Povinelli, Martin R. Matthews, Mark P. Birka, Michael A. West
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Publication number: 20200164929Abstract: A liftgate arrangement including a thermoplastic inner panel with an outer surface and an inner surface. The liftgate arrangement further includes one or more carbon fiber sheet mold compound reinforcements connected to and extending across a portion of the outer surface of the inner panel. The one or more carbon fiber sheet mold compound reinforcements also includes a channel extending between two openings on the one or more carbon fiber sheet mold compound reinforcements. The one or more carbon fiber sheet mold compound reinforcements are used to strengthen the inner panel at desired locations.Type: ApplicationFiled: November 26, 2019Publication date: May 28, 2020Inventors: Christopher John Kuntze, Mark P. Birka, Sinisa Andrasic, Scott Varisto, William J.J. Harney
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Patent number: 10661842Abstract: A modular gate combined with multiple functions which can be easily employed with existing tailgates without any hardware or mounting modifications to existing truck beds. There is provided a modular tailgate system having a tailgate portion in combination with a plurality of functions. The modular tailgate system integrates any combinations of at least two of the plurality of features without affecting existing body sides and/or existing truck beds. Integrated features include a multi-functional gate (e.g., swing, drop, etc), storage (e.g., normal, sealed, refrigerated, heated, etc), step(s), lighting (e.g., ingress/egress, bed interior, removable, trailer hitch, parking, etc), bed extension(s), power (e.g., 12 v and/or 110 v), tie downs (e.g., ratchets, anchors, etc), sawhorse, magnet(s), table(s), bench(es), seat(s), net(s), any other predetermined desired function, etc., and combinations thereof.Type: GrantFiled: August 19, 2015Date of Patent: May 26, 2020Assignee: Magna Exteriors Inc.Inventors: Anthony J. Povinelli, Martin R. Matthews, Mark P. Birka, Michael A. West
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Patent number: 10549611Abstract: An exterior body panel assembly having a Class A painted surface, mold-in color or non-Class A surface, and process of infrared welding components of the assembly. Panels of the assembly are placed on a nesting structure and the inside half of the structures are brought together with the other for a fit check. Panels are separated and an infrared heating fixture then heats the various areas to be heated on the panels. The areas on the panels are heated depending on the thicknesses of the parts at each area and surface geometries to be welded. The parts are immediately clamped back together under pressure for joining and cooling of the joined surfaces in the clamped arrangement.Type: GrantFiled: January 30, 2017Date of Patent: February 4, 2020Assignee: Magna Exteriors Inc.Inventors: Riad Chaaya, Mark P. Birka, William J. J. Harney, Heiner Salzmann, Christopher J. Kuntze, Keijo J. Huotari
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Publication number: 20200009949Abstract: A liftgate assembly having finished show surfaces, and process of manufacturing same. The liftgate assembly includes local reinforcements that are overmolded to first reinforcements, and the first reinforcements are infrared welding to a first panel. Second and third reinforcements are also infrared welded to the first panel. To infrared weld the respective reinforcements to the first panel in predetermined locations with respect to the first panel, nesting structures are provided to hold the respective reinforcements and first panel. At least one infrared heating fixture heats various predetermined surfaces on the reinforcements and first panel, and the parts are then pressed together for joining the predetermined surfaces of the respective parts together. The process is repeated, if needed, until all of the reinforcements are infrared welded to the first panel. Outer panels are bonded to the second and third reinforcements.Type: ApplicationFiled: February 16, 2018Publication date: January 9, 2020Applicant: Magna Exteriors Inc.Inventors: Stanislav TICHY, Mark P. Birka, Riad Chaaya, Paul Hasl
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Patent number: 10479009Abstract: A molded vehicle component (10) having a skin (14) and a lower density core (16) formed by a co-injection molding process. In a first phase, a first material for forming the skin of class A surface material is injected into a mold to partially fill the mold cavity (104). Thereafter, in a second phase, a second material is injected into the same cavity (104) to complete filling of the mold cavity (104). The second material can flow only to portions of the part where the first material is still molten and displaces the molten core of the first phase, pushing it away from co-injection gates until the mold cavity is full. The second material is pre-treated with a chemical blowing agent in order to reduce part weight by foaming the core material. The finished co-injection molded part (10) has one material on all visible class A surfaces (14) and a core (16) that is a different, less dense material.Type: GrantFiled: October 24, 2014Date of Patent: November 19, 2019Assignee: Magna Exteriors Inc.Inventors: Mark P. Birka, Keith G. Korte, Daniel R. Dobbs, Jeremy K. Dew, Charles T. Parker
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Publication number: 20180345767Abstract: An exterior body panel assembly having a Class A painted surface, mold-in color or non-Class A surface, and process of infrared welding components of the assembly. Panels of the assembly are placed on a nesting structure and the inside half of the structures are brought together with the other for a fit check. Panels are separated and an infrared heating fixture then heats the various areas to be heated on the panels. The areas on the panels are heated depending on the thicknesses of the parts at each area and surface geometries to be welded. The parts are immediately clamped back together under pressure for joining and cooling of the joined surfaces in the clamped arrangement.Type: ApplicationFiled: January 30, 2017Publication date: December 6, 2018Applicant: Magna Exteriors Inc.Inventors: Riad Chaaya, Mark P. Birka, William J.J. Harney, Heiner Salzmann, Christopher J. Kuntze, Keijo J. Huotari
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Patent number: 10029410Abstract: An exterior body panel assembly having a Class A painted surface, mold-in color or non-Class A surface, and process of infrared welding components of the assembly. Panels of the assembly are placed on a nesting structure and the inside half of the structures are brought together with the other for a fit check. Panels are separated and an infrared heating fixture then heats the various areas to be heated on the panels. The areas on the panels are heated depending on the thicknesses of the parts at each area and surface geometries to be welded. The parts are immediately clamped back together under pressure for joining and cooling of the joined surfaces in the clamped arrangement.Type: GrantFiled: November 22, 2017Date of Patent: July 24, 2018Assignee: Magna Exteriors Inc.Inventors: Riad Chaaya, Mark P. Birka, William J. J. Harney, Heiner Salzmann, Christopher J. Kuntze, Keijo J. Huotari
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Publication number: 20180104871Abstract: A thermoplastic liftgate inner panel construction is provided by using a co-injected injection molding process. In a first phase, a class A surface material is injected into the molds and thereafter in a second phase an inner core of material is injected using a gas-infused reinforced polymer.Type: ApplicationFiled: November 29, 2017Publication date: April 19, 2018Inventor: Mark P. Birka
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Publication number: 20180104904Abstract: An exterior body panel assembly having a Class A painted surface, mold-in color or non-Class A surface, and process of infrared welding components of the assembly. Panels of the assembly are placed on a nesting structure and the inside half of the structures are brought together with the other for a fit check. Panels are separated and an infrared heating fixture then heats the various areas to be heated on the panels. The areas on the panels are heated depending on the thicknesses of the parts at each area and surface geometries to be welded. The parts are immediately clamped back together under pressure for joining and cooling of the joined surfaces in the clamped arrangement.Type: ApplicationFiled: November 22, 2017Publication date: April 19, 2018Applicant: Magna Exteriors Inc.Inventors: Riad Chaaya, Mark P. Birka, William J.J. Harney, Heiner Salzmann, Christopher J. Kuntze, Keijo J. Huotari