Patents by Inventor Mark W. THIBAULT
Mark W. THIBAULT 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: 10113502Abstract: A cylinder head includes an inner structural member having a plate forming a deck face of the cylinder head and forming at least one dished cylinder roof, and a plurality of cylinder head bolt columns extending from the plate. An outer member is supported by the inner structural member and forms a cooling jacket, intake ports, and exhaust ports. Passages of the cooling jacket are lined with metal walls in contact with the composite structure of the outer member. A method of forming a cylinder head includes positioning a structural insert and a lost core insert in a tool, and injecting material into the tool to form a body surrounding the structural insert and the lost core insert thereby forming a head preform. The lost core insert is shaped to form a cooling jacket and has a lost core material generally encapsulated in a metal shell.Type: GrantFiled: September 8, 2015Date of Patent: October 30, 2018Assignee: Ford Global Technologies, LLCInventors: Clifford E. Maki, Antony George Schepak, Mathew Leonard Hintzen, Mark W. Thibault, Christopher Donald Wicks
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Patent number: 10066577Abstract: Extruded cylinder liners and methods of forming the same are disclosed. The extruded engine cylinder liner may include a cylindrical body having a longitudinal axis and defining an inner surface and an outer surface. A plurality of spaced apart features may protrude from the outer surface and may extend in a direction oblique to the longitudinal axis. The method may include extruding a metal material through a die to form a cylindrical body defining an inner surface and an outer surface and a plurality of spaced apart features protruding from the outer surface. The die may be rotated about a longitudinal axis during at least a portion of the extruding step such that the features extend in a direction oblique to the longitudinal axis. The oblique features may allow parent casting material to enter channels therebetween and prevent the liner from moving in the vertical and horizontal directions.Type: GrantFiled: February 29, 2016Date of Patent: September 4, 2018Assignee: Ford Global Technologies, LLCInventors: Clifford E. Maki, Antony George Schepak, Mathew Leonard Hintzen, James Maurice Boileau, Mark W. Thibault
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Patent number: 10036346Abstract: An engine has a cylinder block formed by a block material and defining at least one cylinder. The block defines a lubrication circuit with fluid passages including an inlet passage, a main oil gallery, a crankshaft bearing lubrication passage, and a piston ring lubrication passage. The fluid passages are formed by continuous metal walls in contact with and surrounded by the block material. At least one of the fluid passages is curved. A method of forming a component with an internal pressurized lubrication circuit includes positioning a lost core insert in a tool, with the insert shaped to form a lubrication circuit. The lost core insert has a lost core material generally encapsulated in a continuous metal shell, and at least one curved section. Material is provided into the tool to form a body surrounding the lost core insert thereby forming a component preform.Type: GrantFiled: September 10, 2015Date of Patent: July 31, 2018Assignee: Ford Global Technologies, LLCInventors: Clifford E. Maki, Antony George Schepak, Mathew Leonard Hintzen, Mark W. Thibault
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Publication number: 20170248097Abstract: Extruded cylinder liners and methods of forming the same are disclosed. The extruded engine cylinder liner may include a cylindrical body having a longitudinal axis and defining an inner surface and an outer surface. A plurality of spaced apart features may protrude from the outer surface and may extend in a direction oblique to the longitudinal axis. The method may include extruding a metal material through a die to form a cylindrical body defining an inner surface and an outer surface and a plurality of spaced apart features protruding from the outer surface. The die may be rotated about a longitudinal axis during at least a portion of the extruding step such that the features extend in a direction oblique to the longitudinal axis. The oblique features may allow parent casting material to enter channels therebetween and prevent the liner from moving in the vertical and horizontal directions.Type: ApplicationFiled: February 29, 2016Publication date: August 31, 2017Inventors: Clifford E. MAKI, Antony George SCHEPAK, Mathew Leonard HINTZEN, James Maurice BOILEAU, Mark W. THIBAULT
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Patent number: 9719461Abstract: An engine includes a cylinder block defining at least one main bearing bulkhead adjacent to a cylinder, and a crankshaft rotatably housed within the block by a main bearing. A bulkhead insert has a cap portion, and an insert portion provided within the bulkhead. The insert portion has having first and second end regions connected by first and second straps. Each strap having a flanged beam cross section. The first and second ends of the insert portion are configured to connect a main bearing cap column to a cylinder head column. Each of the first and second end regions define at least one protrusion having a surface substantially normal to engine combustion and reactive loads. The cap portion is configured to mate with the first end region at the main bearing cap column and support the main bearing.Type: GrantFiled: February 12, 2015Date of Patent: August 1, 2017Assignee: Ford Global Technologies, LLCInventors: Clifford E. Maki, Jeffrey Eliot Chottiner, Rick L. Williams, Mark W. Thibault, James Douglas Ervin, James Maurice Boileau, Bryan McKeough
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Publication number: 20170074205Abstract: An engine has a cylinder block formed by a block material and defining at least one cylinder. The block defines a lubrication circuit with fluid passages including an inlet passage, a main oil gallery, a crankshaft bearing lubrication passage, and a piston ring lubrication passage. The fluid passages are formed by continuous metal walls in contact with and surrounded by the block material. At least one of the fluid passages is curved. A method of forming a component with an internal pressurized lubrication circuit includes positioning a lost core insert in a tool, with the insert shaped to form a lubrication circuit. The lost core insert has a lost core material generally encapsulated in a continuous metal shell, and at least one curved section. Material is provided into the tool to form a body surrounding the lost core insert thereby forming a component preform.Type: ApplicationFiled: September 10, 2015Publication date: March 16, 2017Inventors: Clifford E. MAKI, Antony George SCHEPAK, Mathew Leonard HINTZEN, Mark W. THIBAULT
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Publication number: 20170067413Abstract: A cylinder head includes an inner structural member having a plate forming a deck face of the cylinder head and forming at least one dished cylinder roof, and a plurality of cylinder head bolt columns extending from the plate. An outer member is supported by the inner structural member and forms a cooling jacket, intake ports, and exhaust ports. Passages of the cooling jacket are lined with metal walls in contact with the composite structure of the outer member. A method of forming a cylinder head includes positioning a structural insert and a lost core insert in a tool, and injecting material into the tool to form a body surrounding the structural insert and the lost core insert thereby forming a head preform. The lost core insert is shaped to form a cooling jacket and has a lost core material generally encapsulated in a metal shell.Type: ApplicationFiled: September 8, 2015Publication date: March 9, 2017Inventors: Clifford E. MAKI, Antony George SCHEPAK, Mathew Leonard HINTZEN, Mark W. THIBAULT, Christopher Donald WICKS
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Publication number: 20160237946Abstract: An engine includes a cylinder block defining at least one main bearing bulkhead adjacent to a cylinder, and a crankshaft rotatably housed within the block by a main bearing. A bulkhead insert has a cap portion, and an insert portion provided within the bulkhead. The insert portion has having first and second end regions connected by first and second straps. Each strap having a flanged beam cross section. The first and second ends of the insert portion are configured to connect a main bearing cap column to a cylinder head column. Each of the first and second end regions define at least one protrusion having a surface substantially normal to engine combustion and reactive loads. The cap portion is configured to mate with the first end region at the main bearing cap column and support the main bearing.Type: ApplicationFiled: February 12, 2015Publication date: August 18, 2016Inventors: Clifford E. MAKI, Jeffrey Eliot CHOTTINER, Rick L. WILLIAMS, Mark W. THIBAULT, James Douglas ERVIN, James Maurice BOILEAU, Bryan McKEOUGH