Patents by Inventor Robert Corbly McCune
Robert Corbly McCune 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: 7179539Abstract: An electric machine made from kinetically sprayed permanent magnet material and a binder material form a composite admixture having microstructure of permanent magnet material embedded in the binder material. The admixture has a permanent magnetic moment. The magnets of the present invention may be integrally formed atop carriers to form electrical machines such as motors, generators, alternators, solenoids, and actuators. The manufacturing techniques used in this invention may produce highly defined articles that do not require additional shaping or attaching steps. Very high-purity permanent and soft magnetic materials, and conductors with low oxidation are produced.Type: GrantFiled: July 29, 2002Date of Patent: February 20, 2007Assignee: Ford Global Technologies, LLCInventors: Franco Leonardi, John Matthew Ginder, Robert Corbly McCune
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Patent number: 7097885Abstract: A method of manufacturing electric machines comprised of geometrically patterned arrays of permanent magnets, soft magnetic materials, and electrical conductors deposited by kinetic spraying methods directly atop a carrier. The magnets and planar coils of the present invention may be integrally formed atop carriers to form electrical machines such as motors, generators, alternators, solenoids, and actuators. The manufacturing techniques used in this invention may produce highly defined articles that do not require additional shaping or attaching steps. Very high-purity permanent and soft magnetic materials, and conductors with low oxidation are produced.Type: GrantFiled: June 17, 2003Date of Patent: August 29, 2006Assignee: Ford Global Technologies, LLCInventors: Franco Leonardi, John Matthew Ginder, Robert Corbly McCune
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Patent number: 6773763Abstract: A method of manufacturing a permanent magnet by the steps of preparing an admixture of magnetic material and binder material, the admixture material having a particle size of less than 325 mesh. Then heating a carrier gas to a temperature substantially below the melting point of either component of the admixture. The admixture is introduced into the carrier gas and the admixture is sprayed atop a ductile carrier. The admixture adheres to the carrier and forms a solid permanent magnet. An electric field is applied to the sprayed admixture to create a permanent magnetic moment.Type: GrantFiled: July 29, 2002Date of Patent: August 10, 2004Assignee: Ford Global Technologies, LLCInventors: Franco Leonardi, John Matthew Ginder, Robert Corbly McCune
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Publication number: 20030209286Abstract: A method of manufacturing electric machines comprised of geometrically patterned arrays of permanent magnets, soft magnetic materials, and electrical conductors deposited by kinetic spraying methods directly atop a carrier. The magnets and planar coils of the present invention may be integrally formed atop carriers to form electrical machines such as motors, generators, alternators, solenoids, and actuators. The manufacturing techniques used in this invention may produce highly defined articles that do not require additional shaping or attaching steps. Very high-purity permanent and soft magnetic materials, and conductors with low oxidation are produced.Type: ApplicationFiled: June 17, 2003Publication date: November 13, 2003Applicant: Ford Motor CompanyInventors: Franco Leonardi, John Matthew Ginder, Robert Corbly McCune
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Patent number: 6592935Abstract: A method of manufacturing electric machines comprised of geometrically patterned arrays of permanent magnets, soft magnetic materials, and electrical conductors deposited by kinetic spraying methods directly atop a carrier. The magnets and planar coils of the present invention may be integrally formed atop carriers to form electrical machines such as motors, generators, alternators, solenoids, and actuators. The manufacturing techniques used in this invention may produce highly defined articles that do not require additional shaping or attaching steps. Very high-purity permanent and soft magnetic materials, and conductors with low oxidation are produced.Type: GrantFiled: May 30, 2001Date of Patent: July 15, 2003Assignee: Ford Motor CompanyInventors: Franco Leonardi, John Matthew Ginder, Robert Corbly McCune
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Publication number: 20020182311Abstract: A method of manufacturing electric machines comprised of geometrically patterned arrays of permanent magnets, soft magnetic materials, and electrical conductors deposited by kinetic spraying methods directly atop a carrier. The magnets and planar coils of the present invention may be integrally formed atop carriers to form electrical machines such as motors, generators, alternators, solenoids, and actuators. The manufacturing techniques used in this invention may produce highly defined articles that do not require additional shaping or attaching steps. Very high-purity permanent and soft magnetic materials, and conductors with low oxidation are produced.Type: ApplicationFiled: May 30, 2001Publication date: December 5, 2002Inventors: Franco Leonardi, John Matthew Ginder, Robert Corbly McCune
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Publication number: 20020182313Abstract: A method of manufacturing a permanent magnet by the steps of preparing an admixture of magnetic material and binder material, the admixture material having a particle size of less than 325 mesh. Then heating a carrier gas to a temperature substantially below the melting point of either component of the admixture. The admixture is introduced into the carrier gas and the admixture is sprayed atop a ductile carrier. The admixture adheres to the carrier and forms a solid permanent magnet. An electric field is applied to the sprayed admixture to create a permanent magnetic moment.Type: ApplicationFiled: July 29, 2002Publication date: December 5, 2002Applicant: Ford Motor CompanyInventors: Franco Leonardi, John Matthew Ginder, Robert Corbly McCune
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Publication number: 20020182314Abstract: A method of manufacturing electric machines comprising the steps of kinetically spraying a powdered admixture of magnetic material and ductile binder material on to a substrate and applying a concentrated magnetic field to the sprayed admixture to cause magnetic dipole alignment in the sprayed admixture. The magnets of the present invention may be integrally formed atop carriers to form electrical machines such as motors, generators, alternators, solenoids, and actuators. The manufacturing techniques used in this invention may produce highly defined articles that do not require additional shaping or attaching steps. Very high-purity permanent and soft magnetic materials, and conductors with low oxidation are produced.Type: ApplicationFiled: July 29, 2002Publication date: December 5, 2002Applicant: Ford Motor CompanyInventors: Franco Leonardi, John Matthew Ginder, Robert Corbly McCune
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Publication number: 20020182411Abstract: An electric machine made from kinetically sprayed permanent magnet material and a binder material form a composite admixture having microstructure of permanent magnet material embedded in the binder material. The admixture has a permanent magnetic moment. The magnets of the present invention may be integrally formed atop carriers to form electrical machines such as motors, generators, alternators, solenoids, and actuators. The manufacturing techniques used in this invention may produce highly defined articles that do not require additional shaping or attaching steps. Very high-purity permanent and soft magnetic materials, and conductors with low oxidation are produced.Type: ApplicationFiled: July 29, 2002Publication date: December 5, 2002Applicant: Ford Motor CompanyInventors: Franco Leonardi, John Matthew Ginder, Robert Corbly McCune
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Patent number: 6464933Abstract: A method of fabricating a foamed metal structure using a powder supply of metal particles, comprising: (a) introducing the powder supply along with foaming agent particles into a propellant gas to form a gas/particle mixture stream; (b) projecting the mixture stream at a critical velocity of at least sonic velocity onto a metallic substrate to create a deposit of pressure-welded metal particles containing the admixed foaming agent; and (c) subjecting at least the coating of the substrate to a thermal excursion effective to activate expansion of the foaming agent while softening the metal particles for plastic deformation under the influence of the expanding gases.Type: GrantFiled: June 29, 2000Date of Patent: October 15, 2002Assignee: Ford Global Technologies, Inc.Inventors: Oludele Olusegun Popoola, Ray Jahn, Robert Corbly McCune
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Patent number: 6345440Abstract: A method of making valve guides by thermal spraying a wear-resistant layer onto a rotating mandrel that is subsequently built up by thermal spraying steel on the wear-resistant layer. A flame spray polymer lubricant may be applied to the wear-resistant layer to improve self-lubricating properties of the engine valve guide. The mandrel and applied layers are then cut off and the remaining segment is further processed in a machining operation to remove the mandrel from the inside of the engine valve guide. The mandrel is preferably cooled as the thermal spray is applied preferably by routing a cooling fluid such as air through the mandrel.Type: GrantFiled: July 21, 2000Date of Patent: February 12, 2002Assignee: Ford Global Technologies, Inc.Inventors: Larry Van Reatherford, Oludele Olusegun Popoola, Robert Corbly McCune
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Patent number: 6270849Abstract: A method of manufacturing a metal and polymeric composite article by the following steps. Droplets of spray deposited metal and spray deposited polymeric material are combined to form an article having the polymeric material interspersed within the metal. A carrier or form that shaped to receive the metal and polymeric layers is provided. The carrier may be made either stationary or movable. Layers of spray deposited metal and spray deposited polymeric material are applied atop the carrier. The spray deposited metal is between 90 and 95 percent by volume of the article. The polymeric layers do not completely cover the metal layers. Succeeding spray deposited metal layers contact bond to previous metal layers. The polymeric material between imbedded between the interconnected metal layers.Type: GrantFiled: August 9, 1999Date of Patent: August 7, 2001Assignee: Ford Global Technologies, Inc.Inventors: Oludele Olusegun Popoola, Larry Van Reatherford, Ronald Paul Cooper, Robert Corbly McCune
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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: 6231309Abstract: Transmission torque converter reactor thrust washer segments (12) comprising a surface hardenable aluminum alloy are subjected to electrical discharge machining (EDM) using an electrode (26) and under conditions effective to impart a hydrodynamic bearing surface profile to the segment surfaces (12a), reduce segment surface roughness, and increase segment surface hardness. Torque converter reactors (10) having integrated thrust washer segments machined in this manner exhibit improved wear resistance and hydrodynamic lift when compared to as cast thrust washer segments.Type: GrantFiled: June 18, 1999Date of Patent: May 15, 2001Assignee: Ford Global Technologies, Inc.Inventors: Oludele Olusegun Popoola, Larry Van Reatherford, Robert Corbly McCune, Ronald Paul Cooper
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Patent number: 6017591Abstract: A method of defining valve seats on valve seat supports of an internal combustion engine head. The method includes steps of; (a) roughening the exposed surface of the valve seat support to a finish of 10-50 .mu.m RA; (b) thermally spraying a stream of composite particles onto the roughened support surface, using gaseous propellants with sufficient heat and force to produce a dense adherent composite coating of metal and metal oxide particles and to a thickness no greater than 1-1.5 mm; and (c) finish machining if necessary, the sprayed coating to define the valve seat surface. The composite coated product consists of a metal/metal oxide mixture that possesses one or more of the following characteristics: a surface porosity of 2-5%, a density of 6.5-8 grams/cc, a Vickers hardness of about 280 kg/mm.sup.2 at 450.degree. C., high wear resistance and high corrosion resistance.Type: GrantFiled: November 14, 1996Date of Patent: January 25, 2000Assignee: Ford Global Technologies, Inc.Inventors: Oludele Olusegun Popoola, Robert Corbly McCune, Larry Van Reatherford, Eddie Lee Cartwright
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Patent number: 5983495Abstract: Method of making seat inserts by thermally spraying bulk material. The method includes the steps of: (i) preparing a mandrel having an outside dimension not greater than the desired inside dimension of the desired insert, the mandrel having a part to provide for separation of the sprayed bulk material from the mandrel, (ii) thermal spraying separate particles of one or more types of steel or nickel alloys in the presence of a controlled oxidizing medium to form a bulk composite material on the mandrel with a density of at least 99% and, (iii) after cooling the bulk material, removing such material from the mandrel and slicing it into discrete seat shapes for implanting into the final product.Type: GrantFiled: December 29, 1997Date of Patent: November 16, 1999Assignee: Ford Global Technologies, Inc.Inventors: Oludele Olusegun Popoola, Larry Van Reatherford, Robert Corbly McCune, Armando Mateo Joaquin, Eddie Lee Cartwright
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Patent number: 5976704Abstract: A composite metallizing wire useful in thermal flame spraying, having a conductive metallic solid core wire strand and a coating consisting of solid lubricant particles (i.e., graphite, BN, Teflon) and wear-resistant particles (i.e., SiC, TiC, Cr.sub.3 C.sub.2) homogeneously suspended in a conductive metal (i.e., Ni, Fe, Cr, Mo, Ti) complementary to said solid core wire strand.A method of making such composite metallizing wire useful in thermal flame spraying, comprising submersing a solid core wire mandrel of conductive metal in a plating bath to act as a cathode, the bath containing conductive metal salt and an electrolyte having a salt with a depositable metal and a dispersant of wear-resistant particles (i.e., in an amount of from 20-150 grams/liter) and solid lubricant particles (i.e., in an amount of from 10-200 grams/liter), and energizing the electrolyte to codeposit metal from said electrolyte along with wear-resistant particles and solid lubricant particles onto said wire mandrel.Type: GrantFiled: August 14, 1995Date of Patent: November 2, 1999Assignee: Ford Global Technologies, Inc.Inventor: Robert Corbly McCune