Patents by Inventor Paul Earl Pergande
Paul Earl Pergande 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: 6470954Abstract: A method of spray forming a weldable metal deposit. The method comprises (a) providing a ceramic spray forming pattern, (b) heating the spray forming pattern to a sustained temperature sufficient to prevent internal stress formation in deposited carbon steel having a carbon content of less than about 0.3 weight percent when deposited on the heated spray forming pattern, (c) spraying metallic particles onto the spray forming pattern heated to the sustained temperature, and (d) allowing the sprayed metallic particles to cool to form a metal deposit. The metallic particles have a carbon content which is sufficient to result in metal particles having a carbon content of less than about 0.3 weight percent when deposited on the heated spray forming pattern. The resulting deposit has a carbon content of less than about 0.3 weight percent.Type: GrantFiled: June 6, 2001Date of Patent: October 29, 2002Assignee: Ford Global Technologies, Inc.Inventors: Jeffrey Alan Kinane, David Robert Collins, Matthew John Zaluzec, Paul Earl Pergande, Grigoriy Grinberg
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Patent number: 6331680Abstract: A multilayer, monolithic electrical interconnection device includes a substrate and a plurality of overlaying, alternating conducting and insulating layers deposited atop the substrate and one another. The layers are deposited by thermal spraying of respective insulating or conducting material through defined apertures in respective spray masks. Interlayer electrical connections are intrinsically formed by direct metallurgical bonding between the conducting material of an overlaying layer and the conducting material of a previously sprayed layer.Type: GrantFiled: August 7, 1996Date of Patent: December 18, 2001Assignee: Visteon Global Technologies, Inc.Inventors: David John Klassen, Morgan Merritt Whitney, Jr., Thomas Randall Peterman, Paul Earl Pergande, David Robert Collins
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Patent number: 6308765Abstract: The present invention relates to a method of making a molding tool comprising a core die and a cavity die. The method comprises (a) providing a first metal deposit comprising one of the cavity die or the core die, the first metal deposit having a die face, (b) providing a spray forming pattern on a portion of the die face of the first metal deposit,(c) spraying metal particles onto the first metal deposit and the spray forming pattern to form a second metal deposit comprising the other of the cavity die or the core die, and (d) removing the spray forming pattern from the first and second metal deposits.Type: GrantFiled: November 4, 1998Date of Patent: October 30, 2001Inventors: Grigoriy Grinberg, David Robert Collins, Jeffrey Alan Kinane, Paul Earl Pergande
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Patent number: 6297466Abstract: A machine tool or die that is fabricated from thermally spray-formed steel is repaired on the factory floor by first cleaning the area to be repaired to removed all dirt and impurities. Next the surface is prepared by means of preheating the surface with propane torches at a rate not exceeding 50° Centigrade per hour to boil off the moisture in the tool. The weldment is formed by the TIG welding process and then finished by conventional machining, grinding and polishing.Type: GrantFiled: October 12, 1999Date of Patent: October 2, 2001Assignee: Ford Motor CompanyInventors: Nakhleh Hussary, Paul Earl Pergande
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Publication number: 20010023754Abstract: A method of spray forming a weldable metal deposit. The method comprises (a) providing a ceramic spray forming pattern, (b) heating the spray forming pattern to a sustained temperature sufficient to prevent internal stress formation in deposited carbon steel having a carbon content of less than about 0.3 weight percent when deposited on the heated spray forming pattern, (c) spraying metallic particles onto the spray forming pattern heated to the sustained temperature, and (d) allowing the sprayed metallic particles to cool to form a metal deposit. The metallic particles have a carbon content which is sufficient to result in metal particles having a carbon content of less than about 0.3 weight percent when deposited on the heated spray forming pattern. The resulting deposit has a carbon content of less than about 0.3 weight percent.Type: ApplicationFiled: June 6, 2001Publication date: September 27, 2001Applicant: Ford Global Technologies, Inc.Inventors: Jeffrey Alan Kinane, David Robert Collins, Matthew John Zaluzec, Paul Earl Pergande, Grigoriy Grinberg
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Patent number: 6257309Abstract: A method of spray forming a weldable metal deposit. The method comprises (a) providing a ceramic spray forming pattern, (b) heating the spray forming pattern to a sustained temperature sufficient to prevent internal stress formation in deposited carbon steel having a carbon content of less than about 0.3 weight percent when deposited on the heated spray forming pattern, (c) spraying metallic particles onto the spray forming pattern heated to the sustained temperature, and (d) allowing the sprayed metallic particles to cool to form a metal deposit. The metallic particles have a carbon content which is sufficient to result in metal particles having a carbon content of less than about 0.3 weight percent when deposited on the heated spray forming pattern. The resulting deposit has a carbon content of less than about 0.3 weight percent.Type: GrantFiled: November 4, 1998Date of Patent: July 10, 2001Assignee: Ford Global Technologies, Inc.Inventors: Jeffrey Alan Kinane, David Robert Collins, Matthew John Zaluzec, Paul Earl Pergande, Grigoriy Grinberg
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Patent number: 6258402Abstract: A machine tool or die that is fabricated from thermally spray-formed steel is easily repaired by cleaning, roughing and covering the surface to be repaired by a cold-spray layer of metal and then forming a weldment by conventional electric welding processes. The repaired surface is then finished by conventional machining, grinding and polishing and then the tool is put back into service.Type: GrantFiled: October 12, 1999Date of Patent: July 10, 2001Inventors: Nakhleh Hussary, Paul Earl Pergande, Robert Corbly McCune
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Patent number: 6245436Abstract: Aluminum or aluminum alloy bodies, such as cast fuel pump bodies, are subjected to anodic spark deposition under deposition conditions in an electrolyte effective to form an surface layer that is enriched in alpha alumina to improve surface hardness and that includes a substantially uniform distribution of lubricant-retaining, nanosize surface pores.Type: GrantFiled: February 8, 1999Date of Patent: June 12, 2001Inventors: David Boyle, David Robert Collins, Oludele Olusegun Popoola, Paul Earl Pergande, Tony Leung Wong
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Patent number: 6179039Abstract: A method of reducing distortion in a spray formed rapid tool includes the steps of making a model of a desired tool and constructing a ceramic pattern as the inverse of the model. The method also includes the steps of building a thermal model of the desired tool from a solid model of the ceramic pattern and applying thermal boundary conditions to the thermal model based on known conditions. The method also includes the steps of running the thermal model to produce a temperature distribution of the desired tool and determining any temperature deviations in the temperature distribution above a predetermined value. The method further includes thermally spraying a metal material against the ceramic pattern to form the desired tool if there are no temperature deviations in the temperature distribution above the predetermined value.Type: GrantFiled: March 25, 1999Date of Patent: January 30, 2001Assignee: Visteon Global Technologies, Inc.Inventors: Grigoriy Grinberg, Charles Chen, David Robert Collins, Jeffrey Alan Kinane, Paul Earl Pergande
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Patent number: 6155330Abstract: A spray forming pattern of a first metal having a melting point at a first temperature is formed. The spray forming pattern has a surface defining a cavity that has the shape of a master pattern. Steel particles having a carbon content in the range of 0.01-0.9% by weight are sprayed onto the spray forming pattern to form a deposit on the spray forming pattern. The deposit has a thickness of at least 0.5 inches and the temperature of the steel particles increases as the thickness of the steel deposit increases. The spraying conditions are controlled so that the steel particles coming into contact with the spray forming pattern results in a surface temperature of the spray forming pattern of less than about 80.degree. C. The deposit and the spray forming pattern are heated to a second temperature, which is higher than the first temperature, to melt the spray forming pattern from the deposit. The resulting deposit has the general shape of the master pattern.Type: GrantFiled: November 4, 1998Date of Patent: December 5, 2000Assignee: Visteon Global Technologies, Inc.Inventors: Jeffrey Alan Kinane, Grigoriy Grinberg, David Robert Collins, Paul Earl Pergande
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Patent number: 6085413Abstract: A multilayer, monolithic electrical interconnection device includes a substrate and a plurality of overlaying, alternating conducting and insulating layers deposited atop the substrate and one another. The layers are deposited by thermal spraying of respective insulating or conducting material through defined apertures in respective spray masks. Interlayer electrical connections are intrinsically formed by direct metallurgical bonding between the conducting material of an overlaying layer and the conducting material of a previously sprayed layer.Type: GrantFiled: February 2, 1998Date of Patent: July 11, 2000Assignee: Ford Motor CompanyInventors: David John Klassen, Morgan Merritt Whitney, Jr., Thomas Randall Peterman, Paul Earl Pergande, David Robert Collins
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Patent number: 6060117Abstract: Method of making a mask assembly by providing a heat resistance mask substrate having an exposed surface with a surface smoothness less than 2000 micro inches, uniformly spraying a thermoset epoxy organic coating onto such exposed surface in one or more layers to provide a coating having (e.g., a thickness equal to or less than about 0.005 inches), a smoothness characterized by an average profilometer reading (Ra) of no greater than 1.5 micrometers, said coating being devoid of pores that exceed about 0003 inch in size, and flame polishing all or a portion of such coating to effect a surface finish of about 1.0 micrometers. A mask assembly which is useful in masking areas from thermal spray particles, comprising a heat resistance substrate presenting an exposed grit blasted surface having a smoothness of less than 2000, and a thin thermoset epoxy coating bonded to said exposed surface and having a surface smoothness characterized by an average profilometer reading (Ra) no greater than 1.5.Type: GrantFiled: August 31, 1998Date of Patent: May 9, 2000Assignee: Ford Global Technologies, Inc.Inventors: Paul Earl Pergande, Jeffrey Alan Kinane, Deborah Rose Pank, David Robert Collins
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Patent number: 5947179Abstract: Method of sprayforming bulk metal deposits that replicate a master pattern: (i) casting and solidifying ceramic about a master pattern to form a spraying pattern; (ii) after removing the spraying pattern from the master pattern, heating the ceramic spraying pattern to a sustained temperature to effect an isothermal diffusion dependent microstructural transformation; (iii) while in such heated condition, thermally spraying allotropic metal particles onto the heated spraying pattern to form a deposit having a bulk thickness, the particles impacting the spraying pattern, or previously deposited particles, at a temperature above the sustained temperature of the spraying pattern; (iv) holding the deposit on the heated spraying pattern sufficiently long enough to allow the particles of the deposit to undergo a diffusion reaction that relieves internal stresses due to deposition and solidification; and (v) thereafter gradually cooling the deposit to room temperature to produce a unitary article with essentially no dType: GrantFiled: July 30, 1998Date of Patent: September 7, 1999Assignee: Ford Motor CompanyInventors: Jeffrey Alan Kinane, David Robert Collins, Grigoriy Grinberg, Paul Earl Pergande
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Patent number: 5900282Abstract: A method of depositing a dielectric coating, comprising the steps of forming an unroughened or roughened, as-cast or wrought substrate surface to receive the coatings; and flame spraying a single premixed thermoplastic epoxy/hardener powder onto the surface, the resultant in-flight heated powder being chemically activated to impact the surface and form a chemically adhering coating, the coating being cured in-situ to be dielectric and thermally conductive.Type: GrantFiled: January 20, 1998Date of Patent: May 4, 1999Assignee: Ford Global Tech nologies, Inc.Inventors: David Robert Collins, Paul Earl Pergande, Matthew John Zaluzec, Armando Mateo Joaquin, Jeffrey Alan Kinane