Patents by Inventor Richard J. Osborne
Richard J. Osborne 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: 9999921Abstract: A method of making a reinforced metal alloy component, the method including introducing a reinforcing phase precursor into a bulk alloy that is selected from the group consisting of high-entropy alloys, aluminum-based alloys, magnesium-based alloys and combinations thereof. The precursor is converted to a reinforcing phase by exposing the bulk alloy and precursor to an elevated temperature during one or more of a subsequent heat treating step, squeeze casting shaping or semi-solid metal shaping.Type: GrantFiled: June 15, 2015Date of Patent: June 19, 2018Assignee: GM GLOBAL TECHNOLOGY OPERATIOINS LLCInventors: Yucong Wang, Richard J. Osborne, Brian J. McClory
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Publication number: 20180056384Abstract: A casting system includes a first mold, a second mold, the first mold and the second mold being configured to receive molten metal, the first mold and the second mold exerting pressure on the molten metal to form a mechanical component as the molten metal cools, and a sensor that measures the pressure exerted on the molten metal to provide feedback information to regulate the pressure exerted on the molten metal.Type: ApplicationFiled: August 24, 2016Publication date: March 1, 2018Inventors: Richard J. Osborne, Herbert W. Doty, Frank Sant
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Publication number: 20180029113Abstract: A casting system includes a pour cup, a plurality of runners that receive molten metal from the pouring cup, a top mold and a bottom mold that receive the molten metal from the plurality of runners, and a plurality of slides positioned within the top mold and the bottom mold. The positioning of the plurality of slides applies direct pressure on the molten metal in the top mold and the bottom mold to form a cast structural component.Type: ApplicationFiled: July 29, 2016Publication date: February 1, 2018Inventors: Richard J. Osborne, Qigui Wang, Frank Sant
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Patent number: 9839959Abstract: A number of variations may include at least one mold portion that may define a first cavity, a circular gating system, and at least one sprue. The circular gating system may surround the first cavity and define a continuous in-gate from the circular gating to the first cavity. The at least one sprue and at least one vent may be in fluid communication with the circular gating system and the first cavity.Type: GrantFiled: December 17, 2014Date of Patent: December 12, 2017Assignee: GM Global Technology Operations LLCInventors: Richard J. Osborne, Qigui Wang, Frank Sant
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Publication number: 20160361764Abstract: A method of making a reinforced metal alloy component, the method including introducing a reinforcing phase precursor into a bulk alloy that is selected from the group consisting of high-entropy alloys, aluminum-based alloys, magnesium-based alloys and combinations thereof. The precursor is converted to a reinforcing phase by exposing the bulk alloy and precursor to an elevated temperature during one or more of a subsequent heat treating step, squeeze casting shaping or semi-solid metal shaping.Type: ApplicationFiled: June 15, 2015Publication date: December 15, 2016Inventors: Yucong Wang, Richard J. Osborne, Brian J. McClory
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Publication number: 20160175922Abstract: A number of variations may include at least one mold portion that may define a first cavity, a circular gating system, and at least one sprue. The circular gating system may surround the first cavity and define a continuous in-gate from the circular gating to the first cavity. The at least one sprue and at least one vent may be in fluid communication with the circular gating system and the first cavity.Type: ApplicationFiled: December 17, 2014Publication date: June 23, 2016Inventors: RICHARD J. OSBORNE, QIGUI WANG, FRANK SANT
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Patent number: 9205487Abstract: Integrated devices and methods for compensating electric grade steel lamination stack height for use in a conventional two-plate high pressure die cast tool used for casting aluminum induction rotors. These devices and methods allow for significant variation in the lamination stack height without associated failures related to stack height variation, and also ensure constant and accurate clamping pressure on both the OD and ID of the steel lamination stack which prevents electric insulation damage, metal flow between laminations, large casting metal flash, and tool damage for excessive height laminations stacks. The clamping pressure is adjustable and is actuated from a single hydraulic cylinder which allows for a wide range of pressures to accommodate fine adjustment of clamping pressure to insure no damage occurs to the laminations.Type: GrantFiled: December 13, 2013Date of Patent: December 8, 2015Assignee: GM Global Technology Operations LLCInventors: Richard J. Osborne, Kevin P. Coleman, Margarita P. Thompson, Qigui Wang
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Publication number: 20150165523Abstract: Integrated devices and methods for compensating electric grade steel lamination stack height for use in a conventional two-plate high pressure die cast tool used for casting aluminum induction rotors. These devices and methods allow for significant variation in the lamination stack height without associated failures related to stack height variation, and also ensure constant and accurate clamping pressure on both the OD and ID of the steel lamination stack which prevents electric insulation damage, metal flow between laminations, large casting metal flash, and tool damage for excessive height laminations stacks. The clamping pressure is adjustable and is actuated from a single hydraulic cylinder which allows for a wide range of pressures to accommodate fine adjustment of clamping pressure to insure no damage occurs to the laminations.Type: ApplicationFiled: December 13, 2013Publication date: June 18, 2015Applicant: GM Global Technology Operations LLCInventors: Richard J. Osborne, Kevin P. Coleman, Margarita P. Thompson, Qigui Wang
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Patent number: 8684257Abstract: A plurality of conductor bars are positioned within slots of a laminated electric steel disc stack, and the ends of the conductor bars are brazed to end rings to manufacture a rotor. The method includes inserting the conductor bars into the slots of the disc stack, providing the end rings with slots for receiving the ends of the conductor bars; positioning spacers of braze material adjacent each end of each of the conductor bars to create a gap between the end rings and the steel disc stack; and applying heat to melt the braze material of the spacers whereby braze material is furnished by the spacers of braze material to braze the first and second ends of the conductor bars to the first and second end rings. Channels are provided in the face of the end rings facing the steel disc stack to drain away excess braze material.Type: GrantFiled: August 15, 2011Date of Patent: April 1, 2014Assignee: GM Global Technology Operations LLCInventors: Richard J. Osborne, Qigui Wang, Yucong Wang
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Method of manufacturing an end ring over pre-formed conductor bars of a rotor for an electric device
Patent number: 8424188Abstract: A method of manufacturing a rotor assembly includes positioning a laminated stack of electric steel sheets with a plurality of conductor bars positioned within longitudinal grooves defined by the laminated stack in a mold, and casting an end ring in place over ends of the conductor bars. In order to cast the end ring in place, heated liquid aluminum is injected into a cavity defining the end ring, and circulated within the cavity and around the ends of the conductor bars to create relative movement between the liquid aluminum and the ends of the conductor bars to heat the conductor bars and flush oxides away from an outer surface of the conductor bars.Type: GrantFiled: February 23, 2011Date of Patent: April 23, 2013Assignee: GM Global Technology Operations LLCInventors: Qigui Wang, Richard J. Osborne, Yucong Wang -
Publication number: 20130043760Abstract: A plurality of conductor bars are positioned within slots of a laminated electric steel disc stack, and the ends of the conductor bars are brazed to end rings to manufacture a rotor. The method includes inserting the conductor bars into the slots of the disc stack, providing the end rings with slots for receiving the ends of the conductor bars; positioning spacers of braze material adjacent each end of each of the conductor bars to create a gap between the end rings and the steel disc stack; and applying heat to melt the braze material of the spacers whereby braze material is furnished by the spacers of braze material to braze the first and second ends of the conductor bars to the first and second end rings. Channels are provided in the face of the end rings facing the steel disc stack to drain away excess braze material.Type: ApplicationFiled: August 15, 2011Publication date: February 21, 2013Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLCInventors: Richard J. Osborne, Qigui Wang, Yucong Wang
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Patent number: 8344577Abstract: Squirrel cage rotors of aluminum end rings solid state welded to aluminum conductor bars for use in electric motors and methods of making them are described. In one embodiment, the method includes: providing a laminated steel stack having a plurality of longitudinal slots; placing a plurality of aluminum conductor bars in the longitudinal slots, the conductor bars having first and second ends extending out of the longitudinal slots; contacting the first and second ends of the conductor bars with a pair of aluminum end rings under pressure; and oscillating the first and second ends of the conductor bars, the end rings, or both to form an oscillation friction weld.Type: GrantFiled: August 31, 2010Date of Patent: January 1, 2013Assignee: GM Global Technology Operations LLCInventors: Richard J. Osborne, Yucong Wang, Qigui Wang
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METHOD OF MANUFACTURING AN END RING OVER PRE-FORMED CONDUCTOR BARS OF A ROTOR FOR AN ELECTRIC DEVICE
Publication number: 20120210563Abstract: A method of manufacturing a rotor assembly includes positioning a laminated stack of electric steel sheets with a plurality of conductor bars positioned within longitudinal grooves defined by the laminated stack in a mold, and casting an end ring in place over ends of the conductor bars. In order to cast the end ring in place, heated liquid aluminum is injected into a cavity defining the end ring, and circulated within the cavity and around the ends of the conductor bars to create relative movement between the liquid aluminum and the ends of the conductor bars to heat the conductor bars and flush oxides away from an outer surface of the conductor bars.Type: ApplicationFiled: February 23, 2011Publication date: August 23, 2012Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLCInventors: Qigui Wang, Richard J. Osborne, Yucong Wang -
Publication number: 20120049687Abstract: Squirrel cage rotors of aluminum end rings solid state welded to aluminum conductor bars for use in electric motors and methods of making them are described. In one embodiment, the method includes: providing a laminated steel stack having a plurality of longitudinal slots; placing a plurality of aluminum conductor bars in the longitudinal slots, the conductor bars having first and second ends extending out of the longitudinal slots; contacting the first and second ends of the conductor bars with a pair of aluminum end rings under pressure; and oscillating the first and second ends of the conductor bars, the end rings, or both to form an oscillation friction weld.Type: ApplicationFiled: August 31, 2010Publication date: March 1, 2012Applicant: GM GLOBAL TECHNOLOGY OPERATIONS, INC.Inventors: Richard J. Osborne, Yucong Wang, Qigui Wang
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Patent number: 5524696Abstract: A "lost foam" method of making a casting having a preform embedded at a selective location therein including the steps of: engulfing a porous preform in a fugitive pattern; embedding the pattern in a loose sand mold in a vessel; pouring molten metal into the mold cavity via a sprue and runner system formed in the sand bed so as to destroy the pattern and fill the mold cavity with metal; pressurizing the vessel to force molten metal from the cavity into the porous preform; replacing metal lost from the cavity with make-up metal from the sprue and runner system; allowing the casting to solidify; and removing the casting from the sand bed.Type: GrantFiled: August 5, 1994Date of Patent: June 11, 1996Assignee: General Motors CorporationInventors: Richard J. Osborne, Gregory Sanders, Lori J. Sullivan
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Patent number: 5000244Abstract: In a preferred embodiment, a compound aluminium alloy engine block casting comprises at least a piston-travel region of a cylinder wall section formed of a first alloy, preferably hypereutectic aluminum-silicon alloy, and a remainder including a crankcase section and a water jacket wall formed of a distinct second alloy, preferably hypoeutectic aluminum-silicon alloy. The engine block casting is made by a lost foam process that employs an expendable pattern formed of expanded polystyrene or the like. The pattern comprises a first runner system for casting the first alloy to decompose and replace a portion of the pattern corresponding to the piston-travel region of the casting, and a second runner system for casting the second alloy to decompose and replace the remainder of the pattern. The first alloy and the second alloy are independently but concurrently cast into a singular mold, such that the entire pattern is duplicated, whereupon the alloys merge and fuse to form an integral casting.Type: GrantFiled: December 4, 1989Date of Patent: March 19, 1991Assignee: General Motors CorporationInventor: Richard J. Osborne