Patents by Inventor Stephen A. Hutchins

Stephen A. Hutchins 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).

  • Patent number: 11486051
    Abstract: There is disclosed a method of forming a high luminosity inorganic coating on an aluminium or aluminium alloy article, wherein the article is immersed in an electrolyte and subjected to a plasma anodising process, wherein the coating has a luminosity L*?80.0% and comprises at least 50 wt % gamma alumina. Also disclosed are inorganic coatings formed by the method, and aluminium or aluminium alloys coated by the method.
    Type: Grant
    Filed: June 16, 2017
    Date of Patent: November 1, 2022
    Assignee: Keronite International Limited
    Inventors: Stephen Hutchins, Suman Shrestha
  • Publication number: 20190177868
    Abstract: There is disclosed a method of forming a high luminosity inorganic coating on an aluminium or aluminium alloy article, wherein the article is immersed in an electrolyte and subjected to a plasma anodising process, wherein the coating has a luminosity L*?80.0% and comprises at least 50 wt % gamma alumina. Also disclosed are inorganic coatings formed by the method, and aluminium or aluminium alloys coated by the method.
    Type: Application
    Filed: June 16, 2017
    Publication date: June 13, 2019
    Inventors: Stephen Hutchins, Suman Shrestha
  • Patent number: 10208393
    Abstract: There is disclosed an insulated metal substrate, consisting of a dielectric oxide coatings of high crystallinity (>vol 90%) on aluminium, magnesium or titanium and high thermal conductivity (over 6 Wm?1K?1), formed by plasma electrolytic oxidation on a surface comprising aluminium, magnesium or titanium. There is also disclosed a plasma electrolytic oxidation process for generating dielectric oxide coatings of controlled crystallinity on a surface of a metallic workpiece, wherein at least a series of positive pulses of current are applied to the workpiece in an electrolyte so as to generate plasma discharges, wherein discharge currents are restricted to levels no more than 50 mA, discharge durations are restricted to durations of no more than 100 ?s and are shorter than the durations of each the positive pulses, and/or by restricting the power of individual plasma discharges to under 15W.
    Type: Grant
    Filed: July 16, 2014
    Date of Patent: February 19, 2019
    Assignee: Keronite International Limited
    Inventors: James Andrew Curran, Stephen Hutchins
  • Patent number: 9816188
    Abstract: A process for the corrosion protection of metals such as magnesium, aluminium or titanium, where at least two steps are used, including both plasma electrolytic oxidation and chemical passivation. The combination of these two processing steps enhances the corrosion resistance performance of the surface beyond the capability of either of the steps in isolation, providing a more robust protection system. This process may be used as a corrosion protective coating in its own right, or as a protection-enhancing pre-treatment for top-coats such as powder coat or e-coat. When used without an additional top-coat, the treated parts can still retain electrical continuity with and adjoining metal parts. Advantages include reduced cost and higher productivity than traditional plasma-electrolytic oxidation systems, improved corrosion protection, greater coating robustness and electrical continuity.
    Type: Grant
    Filed: March 30, 2010
    Date of Patent: November 14, 2017
    Assignee: Keronite International Limited
    Inventors: James Curran, Stephen Hutchins, Suman Shrestha
  • Patent number: 9765440
    Abstract: There is disclosed a method for producing corrosion and erosion-resistant mixed oxide coatings on a metal substrate, as well as a mixed oxide coating itself. A surface of the substrate metal is oxidized and converted into a first coating compound comprising a primary oxide of that metal by a plasma electrolytic oxidation (PEO) process. One or more secondary oxide compounds comprising oxides of secondary elements not present in conventional alloys of the substrate metals at significant (>2 wt %) levels are added to the first oxide coating. The source of the secondary element(s) is at least one of: i) a soluble salt of the secondary element(s) in the electrolyte; ii) an enrichment of the surface of the substrate metal with secondary element(s) prior to PEO processing; and iii) a suspension of the secondary element(s) or oxide(s) of the secondary element(s) applied to the oxide of the metal after this has been formed by the PEO process.
    Type: Grant
    Filed: April 29, 2014
    Date of Patent: September 19, 2017
    Assignee: Keronite International Limited
    Inventors: James Curran, Stephen Hutchins, Oleg Dunkin
  • Publication number: 20160153111
    Abstract: There is disclosed an insulated metal substrate, consisting of a dielectric oxide coatings of high crystallinity (>vol 90%) on aluminium, magnesium or titanium and high thermal conductivity (over 6 Wm?1K?1), formed by plasma electrolytic oxidation on a surface comprising aluminium, magnesium or titanium. There is also disclosed a plasma electrolytic oxidation process for generating dielectric oxide coatings of controlled crystallinity on a surface of a metallic workpiece, wherein at least a series of positive pulses of current are applied to the workpiece in an electrolyte so as to generate plasma discharges, wherein discharge currents are restricted to levels no more than 50 mA, discharge durations are restricted to durations of no more than 100 ?s and are shorter than the durations of each the positive pulses, and/or by restricting the power of individual plasma discharges to under 15W.
    Type: Application
    Filed: July 16, 2014
    Publication date: June 2, 2016
    Inventors: James Andrew Curran, Stephen Hutchins, Oleg Dunkin
  • Publication number: 20140318974
    Abstract: There is disclosed a method for producing corrosion and erosion-resistant mixed oxide coatings on a metal substrate, as well as a mixed oxide coating itself. A surface of the substrate metal is oxidised and converted into a first coating compound comprising a primary oxide of that metal by a plasma electrolytic oxidation (PEO) process. One or more secondary oxide compounds comprising oxides of secondary elements not present in conventional alloys of the substrate metals at significant (>2 wt %) levels are added to the first oxide coating. The source of the secondary element(s) is at least one of: i) a soluble salt of the secondary element(s) in the electrolyte; ii) an enrichment of the surface of the substrate metal with secondary element(s) prior to PEO processing; and iii) a suspension of the secondary element(s) or oxide(s) of the secondary element(s) applied to the oxide of the metal after this has been formed by the PEO process.
    Type: Application
    Filed: April 29, 2014
    Publication date: October 30, 2014
    Applicant: Keronite International Limited
    Inventors: James Curran, Stephen Hutchins, Oleg Dunkin
  • Publication number: 20120031765
    Abstract: A process for the corrosion protection of metals such as magnesium, aluminium or titanium, where at least two steps are used, including both plasma electrolytic oxidation and chemical passivation. The combination of these two processing steps enhances the corrosion resistance performance of the surface beyond the capability of either of the steps in isolation, providing a more robust protection system. This process may be used as a corrosion protective coating in its own right, or as a protection-enhancing pre-treatment for top-coats such as powder coat or e-coat. When used without an additional top-coat, the treated parts can still retain electrical continuity with and adjoining metal parts. Advantages include reduced cost and higher productivity than traditional plasma-electrolytic oxidation systems, improved corrosion protection, greater coating robustness and electrical continuity.
    Type: Application
    Filed: March 30, 2010
    Publication date: February 9, 2012
    Applicant: KERONITE INTERNATIONAL LTD
    Inventors: James Curran, Stephen Hutchins, Suman Shrestha
  • Patent number: 5419754
    Abstract: A knee brace comprising upper and lower leg-engaging/embracing parts (thigh and calf pieces) connectable around upper and lower parts of the leg above and below the knee joint with the upper and lower leg embracing parts having upper and lower brace members respectively interconnected by at least one joint, wherein the at least one joint means each comprises at least one link member pivotally connected at pivot points to rotate about a pivotal axis on each of the brace members with the at least one link member being provided for holding brace members together, and wherein the end region of a first said brace member has a slot defined between two end arm portions and within the slot space or forming a defining portion thereof, a first gear is provided and such is engaged by a second gear on the end of the second brace member which second gear is displaceable in the slot to engage the first gear and wherein the first and second gears each lie on arcs each concentric with the pivot point of the brace member on w
    Type: Grant
    Filed: February 4, 1994
    Date of Patent: May 30, 1995
    Assignee: Robert Johnson
    Inventor: Stephen Hutchins
  • Patent number: D377433
    Type: Grant
    Filed: December 8, 1995
    Date of Patent: January 21, 1997
    Inventors: David A. Funk, Stephen A. Hutchins