Plural Layers Discontinuously Bonded (e.g., Spot-weld, Mechanical Fastener, Etc.) Patents (Class 428/594)
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Patent number: 7690113Abstract: A process for producing a high temperature-resistant structure provides at least one at least partially structured metallic layer. A smooth metallic layer is deformed by a rolling process, in which oil at least partially wets the at least one layer. The oil is at least partially removed. Lubricant is fed onto at least one subsection of the at least one layer. A structure is at least partially shaped. Technical joining connections are produced for fixing the structure.Type: GrantFiled: October 30, 2006Date of Patent: April 6, 2010Assignee: EMITEC Gesellschaft fuer Emissionstechnologie mbHInventor: Kait Althöfer
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Patent number: 7666520Abstract: A honeycomb body includes two opposite end sides, at least one housing and at least one metallic layer forming channels. At least one of the end sides has at least one brazed zone forming a belt-shaped, brazing material-free zone adjacent the housing. A method for producing the honeycomb body, an exhaust-gas treatment component for an internal combustion engine and a motor vehicle having the honeycomb body, are also provided.Type: GrantFiled: March 24, 2008Date of Patent: February 23, 2010Assignee: EMITEC Gesellschaft fuer Emissionstegchnologie mbHInventors: Ludwig Wieres, Jörg Gutowski, Michael Voit, Ferdi Kurth
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Publication number: 20090311549Abstract: Friction stir welding (FSW) processes, systems and the resulting friction stir welded components are disclosed whereby first and second workpieces are welded to one another using a first workpiece having mutually orthogonal structural components and a junction region therebetween which defines a bearing surface of predetermined geometry. A shoulder of a FSW tool may be brought into bearing contact with the bearing surface so that a pin extending from the shoulder of the FSW tool may be advanced into and through the one structural component of the first workpiece at an angle relative thereto so as to thereby form a friction stir weld region between the first and second workpieces. Some preferred embodiments will provide a bearing surface which defines an arcuately concave geometry, in which case the shoulder of the FSW tool defines an arcuately convex geometry conformably mateable with the bearing surface.Type: ApplicationFiled: June 16, 2008Publication date: December 17, 2009Inventors: Fernando Ferreira Fernandez, Marcio Cruz
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Patent number: 7629057Abstract: A preform main body of an iron species preform for forming a metal matrix composite inserted in an aluminum species alloy base material to be cast-in is bored with a first to fourth through holes communicating an inner peripheral face and an outer peripheral face. In a cast-in step, shrinkage in a peripheral direction of the inner peripheral face and the outer peripheral face of the iron species preform in accordance with solidification of the melted aluminum species alloy is uniformly received by shrinkage in accordance with solidification of the melted aluminum species alloy invading the through holes, movement thereof in the peripheral direction is restrained, a clearance can be prevented from being brought about at an interface, a cast-in performance is excellent and a stable bonding strength of the interface is achieved.Type: GrantFiled: September 28, 2006Date of Patent: December 8, 2009Assignees: Fuji Jukogyo Kabushiki Kaisha, Nippon Piston Ring Co., LtdInventors: Teruyuki Oda, Hiroshi Takiguchi
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Patent number: 7622177Abstract: A composite component comprising at least two parts that differ from one another in their respective coefficients of linear thermal expansion is disclosed. These parts are joined by at least one elastic connecting element having a height dimension and a thickness dimension and containing at least one shear element which is deformable in a shear-flexible manner. The height dimension relate to the thickness dimension in the range of 2 to 60. The inventive composite component is especially suitable for making glazing for automotive roofs.Type: GrantFiled: August 23, 2005Date of Patent: November 24, 2009Assignee: Bayer MaterialScience AGInventor: Frank Krause
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Publication number: 20090280349Abstract: The invention relates to an assembly (1) and a method for producing the latter, with a first and second part (2, 3), the first part (2, 3) of which is cold formed and the parts (2, 3) with parallel surface parts (20, 21) and mounting surfaces running at an angle to the latter are provided for arranging them relative to one another without a gap and are joined together at the joint (16) by a weld (17) produced by beam welding. The surface parts (20, 21) are arranged offset relative to one another by an offset (19). One of the parts (2, 3) comprises a mounting projection (6), which forms the mounting surface of the first part (2). The parts (2, 3) are positioned relative to one another so that the second part (3) forms the joint (16) with the first part (2) in the section of the first part (2) at which the dislocation density of the base material is lower than the dislocation density of the joint in a deformation area (18) on the first part (2) produced by cold forming.Type: ApplicationFiled: July 13, 2005Publication date: November 12, 2009Inventors: Markus Bittendorfer, Roland Heiml
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Patent number: 7614201Abstract: The invention provides a sheet metal joint and a method for forming a sheet metal joint. The sheet metal joint includes first and second metal sheets disposed in a parallel relation to one another. Each of the first and second metal sheets has a plurality of perforations with a tang extending from each perforation. The tangs of the second sheet and the tangs of the second metal sheet are curled together in opposite rotational directions. The tangs of the first metal sheet space the first and second metal sheets from one another and the tangs of the second metal sheet substantially fixedly engage the first and second metal sheets with respect to one another.Type: GrantFiled: October 4, 2005Date of Patent: November 10, 2009Assignee: Federal-Mogul World Wide, Inc.Inventors: John L. Cabanski, Thomas O. Zurfluh
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Publication number: 20090208772Abstract: A method of manufacturing welded metal sheets is presented that leaves exposed (i.e., visible) surfaces of the sheets substantially free of any weld marks following welding, without any additional steps performed at the area of the weld following the weld. Thus, manufacturing efficiency may be increased and costs lowered. An apparatus with three stacked metal sheets which may be welded according to the method of manufacturing is also disclosed herein.Type: ApplicationFiled: February 19, 2008Publication date: August 20, 2009Applicant: GM GLOBAL TECHNOLOGY OPERATIONS, INC.Inventor: Alexander D. Khakhalev
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Publication number: 20090190290Abstract: Methods and apparatus for forming a housing, such as for an electronic device, from multi-layer materials are disclosed. The multi-layer materials include at least two layers. Typically, one or more of the layers are metal. However, different layers of the multi-layer materials can be different metals. In one embodiment, an inner layer of the multi-layer materials can be provided with or form internal features that can be for attaching parts or components to the multi-layer materials. In another embodiment, processing of an inner layer of the multi-layer materials can facilitate part formation with increased curvature and/or internal part clearance. In another embodiment, the multi-layer materials can include an intermediate layer that facilitates creation of internal features that can be for attaching parts or components to the multi-layer materials.Type: ApplicationFiled: September 19, 2008Publication date: July 30, 2009Inventors: Stephen Brian Lynch, John Benjamin Filson, Stephen Paul Zadesky, Douglas Weber
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Patent number: 7562805Abstract: A method for gluing and brazing a honeycomb structure includes at least one partially structured foil with a pitch and a wave height. The method includes the steps of choosing a mean brazing material diameter of a powder brazing material, said diameter being 15% smaller than the height of the wave; determining a minimum thickness of the glue strip according to equation; gluing at least partially structured foil within the width of the glue strip on at least part of the wave crests formed by the undulation; brazing the honeycomb structure. The invention also relates to a corresponding honeycomb structure that ensures satisfactory joint connections even when said structure is used in the exhaust systems of automobiles.Type: GrantFiled: September 19, 2006Date of Patent: July 21, 2009Assignee: EMITEC Gesellschaft fuer Emissionstechnologie mbHInventors: Rolf Brück, Kait Althöfer, Jan Hodgson, Arndt-Udo Rolle
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Publication number: 20090123776Abstract: A method and apparatus for producing a metal core sandwich structure that is lightweight and many times stiffer than regular sheet metal, and which is easily formable into curved structures as well as structures having compound curves. In one embodiment, a formed metal core includes a plurality of cells comprising alternating front and rear projections extending outwardly in front of and behind a median plane, with each projection having a bonding surface area or land configured to be brazed or bonded with corresponding external metal sheets on both sides of the formed metal core. A plurality of micro-abrasions or indentations are formed on the bonding lands, allowing stronger brazing or bonding joints to be formed between the metal core and the external metal sheets by facilitating improved capillary action by the metal core during the brazing or bonding process.Type: ApplicationFiled: October 10, 2008Publication date: May 14, 2009Inventor: George C.P. Straza
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Publication number: 20090110949Abstract: A method for fabricating multi-sheet structures in which a first sheet is arranged on a planar support and a blowing agent is placed on at least one selected portion of the first sheet. A second sheet is positioned over the first sheet so that the second sheet overlies the selected portion of the first sheet and the first and second sheets are then secured together by friction stir welding in a pattern which encloses the selected portion of the first sheet. Additional sheets may be secured together in a like fashion. Thereafter, the sheets are heated to a temperature sufficient to decompose the blowing agent.Type: ApplicationFiled: October 31, 2007Publication date: April 30, 2009Applicant: Hitachi, LtdInventors: Qi Yang, Harsha Badarinarayan, Frank Hunt
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Patent number: 7517579Abstract: A bonded structure including one or more substrates bonded together with a tackified amorphous poly-alpha-olefin adhesive composition. One method of making such a bonded structure is carried out by applying a tackified amorphous poly-alpha-olefin adhesive composition to one or more substrates at a temperature of about 170 degrees Celsius or lower, and joining the substrates to themselves or to one another. The bonded structure has a dynamic peel strength between about 400 and about 1000 grams per 25 millimeters. The bonding efficiency of the bonded structure renders the bonded structure suitable for incorporation into a variety of articles, including personal care products, health/medical products, and household/industrial product, for example.Type: GrantFiled: July 18, 2007Date of Patent: April 14, 2009Assignee: Kimberly-Clark Worldwide, Inc.Inventors: Stephen Michael Campbell, Daniel William Hesse, Richard D. Schultz, Mark J. Jung, Richard M. Hansen, Cristian M. Neculescu, Sandra Marie Rogers, Violet May Grube, Rhiannon L. Thoresen, Thomas Michael Killian, Jonathan K. Rice, Palani Raj Ramaswami Wallajapet, Courtney Eileen Shea, Jason Sybren Fairbanks, Prasad Shrikrishna Potnis, Randall J. Palmer
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Publication number: 20090087679Abstract: A method to manufacture tubing includes co-forming a base material strip and a liner material strip into a string of internally-lined tubing and joining edges of the base material strip to form a seam therebetween.Type: ApplicationFiled: October 2, 2007Publication date: April 2, 2009Applicant: Precision Tube Technology, LPInventors: David McCall, Bruce Reichert
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Publication number: 20090023008Abstract: An imaging device is provided, in which a front sheet metal casing and/or a back sheet metal casing can be secured to a top sheet metal casing without the necessity of providing any screw holes in the top surface of the top sheet metal casing in order to secure the top sheet metal casing to the front sheet metal casing and/or the back sheet metal casing. The top sheet metal casing includes a top plate and a secured sheet metal casing secured to the top plate such that at least a portion of its perimeter is spaced apart from the top plate at a predetermined distance. A flange provided to the front or back sheet metal casing is inserted between the top plate and the secured sheet metal plate, so that an engagement pin provided to the secured sheet metal plate is fitted in an engagement hole provided in the flange, thereby securing the front or back sheet metal casing to the top sheet metal casing.Type: ApplicationFiled: July 17, 2008Publication date: January 22, 2009Applicant: MATSUSHITA ELECTRIC INDUSTRIAL CO., LTD.Inventor: Jun SAIKI
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Publication number: 20090011269Abstract: To provide a joint product of a steel product and an aluminum material, and a spot welding method for the joint product, ensuring that spot welding with high bonding strength can be performed. In one embodiment, a steel product 1 having a sheet thickness t1 of 0.3 to 3.0 mm and an aluminum material 2 having a sheet thickness t2 of 0.5 to 4.0 mm are joined together by spot welding to form a joint product of a steel product and an aluminum produce. In this joint product, the nugget area in the joint part is from 20×t20.5 to 100×t20.5 mm2, the area of a portion where the thickness of the interface reaction layer is from 0.5 to 3 ?m is 10×t20.5 mm2 or more, and the difference between the interface reaction layer thickness at the joint part center and the interface reaction layer thickness at a point distant from the joint part center by a distance of one-fourth of the joint diameter Dc is 5 ?m or less.Type: ApplicationFiled: February 21, 2007Publication date: January 8, 2009Inventors: Wataru Urushihara, Mikako Takeda, Katsushi Matsumoto, Jun Katoh
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Publication number: 20080199718Abstract: The present invention relates to a method of brazing articles of stainless steel, which method comprises the following steps: step (i) applying an iron-based brazing filler material to parts of stainless steel; step (ii) optionally assembling the parts; step (iii) heating the parts from step (i) or step (ii) to a temperature of at least about 1000° C. in a non-oxidizing atmosphere, a reducing atmosphere, vacuum or combinations thereof, and heating the parts at the temperature of at least about 1000° C. for at least about 15 minutes; step (iv) providing articles having an average hardness of less than about 600 HV1 of the obtained brazed areas. The present invention relates also to brazed articles of stainless steel.Type: ApplicationFiled: May 24, 2006Publication date: August 21, 2008Applicant: ALFA LAVAL CORPORATE ABInventors: Per Sjodin, Jens Rassmus
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Publication number: 20080182119Abstract: Disclosed is a projection welding method including providing a first metal substrate, a second metal substrate, and a projection material of separate construction from the first metal substrate and the second metal substrate, disposing the metal projection material between the first metal substrate and the second metal substrate, applying a current and pressure to at least one of the first metal substrate and the second metal substrate, melting the metal projection material via the application of the current and pressure, creating a weld between the first metal substrate and the second metal substrate via the melting, and fixedly associating the first metal substrate and the second metal substrate via the weld.Type: ApplicationFiled: January 30, 2007Publication date: July 31, 2008Applicant: GENERAL ELECTRIC COMPANYInventors: Michael Douglas Arnett, Srikanth Chandrudu Kottilingam, Gitahi Charles Mukira, Gene Arthur Murphy, Daniel Anthony Nowak
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Publication number: 20080166581Abstract: A stack of metallic laminations, a metallic lamination and a process for forming a lamination stack. The stack of laminations includes at least one locking lamination provided with at least two locking openings and at least one passage lamination comprising at least two passage openings, each locking lamination incorporating a tab that passes through a passage opening of a lamination seated against the locking lamination, said tab being bent so as to be contained in said passage opening and seated on an edge portion of the latter, deformed to the inside of the locking opening of the locking lamination, and at least one of the parts of locking lamination and passage lamination further comprising a lock means actuating in a lock receiving means provided in the other of said parts.Type: ApplicationFiled: March 16, 2006Publication date: July 10, 2008Applicant: WHIRLPOOL S.A.Inventors: Tarcísio João Grott, Heber De Carvalho Hespanhol, Hermann Otto Knupfer, Anderson Wolf, Gilberto Lenkulkul, Sergio Do Rosario
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Publication number: 20080145688Abstract: The present invention is directed to a process for joining tantalum clad steel structures. The process broadly comprises: a) providing a first tantalum clad section, said first tantalum clad section comprising a tantalum layer over a steel layer, with a bonding layer optionally therebetween, with a portion of said steel layer in an edge region not being covered by said tantalum layer or said bonding layer, b) providing a second tantalum clad section, said second tantalum clad section comprising a tantalum layer over a steel layer, with a bonding layer optionally therebetween, with a portion of said steel layer in an edge region not being covered by said tantalum layer or said bonding layer, c) locating said steel edge regions adjacent each other, d) welding the steel edge regions together, e) cold spraying a tantalum powder onto the welded edge regions and over the tantalum layers adjacent said edge regions thereby joining the tantalum clad steel sections.Type: ApplicationFiled: December 13, 2006Publication date: June 19, 2008Inventors: Steven A. Miller, Leonid N. Shekhter, Stefan Zimmerman
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Patent number: 7288326Abstract: Multifunctional cellular metals (or other materials) for structural applications that are capable of recovering their original (undeformed) shape and thickness after impact or crushing (i.e., self-healing). Alternatively, they may normally be stored or used in their compressed (i.e., crushed) state and deployed when needed to act as energy absorbing structure or packaging (i.e., deployable energy absorber). Additionally, the multifunctional structures may act as an actuator, capable of providing localized or distributed force and displacement, and related methods of using and manufacturing the same. These active cellular metals (or other materials) are composites consisting of conventional metal/alloy truss structures (or other material structures) in combination with shape memory metal/alloy components (or other material components) and offer high specific strength and stiffness, but which are also deployable energy absorbers or self-healing smart structures.Type: GrantFiled: May 30, 2003Date of Patent: October 30, 2007Assignee: University of Virginia Patent FoundationInventors: Dana M. Elzey, Haydn N. G. Wadley
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Patent number: 7201973Abstract: A heat exchanger of the plate-fin type has fins of one metal brazed to a plate made of a different metal for use in oil coolers, condensers, evaporators, and the like. The distortion-prone titanium fins of conventional heat exchangers may be replaced with another metal, such as a stainless steel or a nickel based alloy to provide a structure that is resistant to crushing at the brazing temperature. Fluid or air flow resistance (pressure drop) through the heat exchanger may also be improved if the selected fin metal forms better fin shapes and has fewer burrs than conventional titanium fins. The replacement material may also improve the heat transfer performance of the heat exchanger if the selected fin metal has higher thermal conductivity than titanium.Type: GrantFiled: December 10, 2003Date of Patent: April 10, 2007Assignee: Honeywell International, Inc.Inventors: Matthew J. Pohlman, Salvador L. Hernandez, Nikolay Lewucky, Edward S. Tai
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Patent number: 7199187Abstract: A sheet excellent in mechanical performance such as folding endurance is provided. A sheet having a substrate layer using an impact-resistant styrene type resin containing 2 to 15 wt % of rubber particles having a peak at less than 2 ?m and an impact-resistant styrene type resin containing 0.2 to 10 wt % of rubber particles having a peak at 2 ?m or more in a distribution of volume-based particle diameters, or a sheet having a substrate layer comprising an impact-resistant styrene type resin (A) containing 10 to 15 wt % of rubber having a volume average particle diameter of from 0.5 ?m to 1.5 ?m and an impact-resistant styrene type resin (B) containing 5 to 10 wt % of rubber having a volume average particle diameter of from 2.0 ?m to 3.0 ?m wherein (A) is from 50 to 95 wt % and (B) is from 5 to 50 wt % on the basis of the total amount of both components, and a surface layer formed on at least its one surface, is provided.Type: GrantFiled: November 15, 2002Date of Patent: April 3, 2007Assignee: Denki Kagaku Kogyo Kabushiki KaishaInventors: Takeshi Miyakawa, Minoru Oda, Masafumi Hiura
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Patent number: 7199980Abstract: A head suspension provided with a plate welding structure relaxes a laser beam positioning accuracy, improves a mass production ability, suppresses the generation of spattered matter, and prevents the deformation of plates during welding. The head suspension (1) has a base plate (3) to be attached to a carriage and a load beam (5) having a rigid part (9) and a resilient part (11). The load beam is supported by the base plate and applies load on a slider that is arranged at a front end of the load beam. A reinforcing plate (25) is laid over the base plate, and a laser beam is emitted to a weld spot to weld the reinforcing plate and base plate together. The reinforcing plate is provided with thin parts (29) each containing the weld spot. Each thin part is irradiated with a laser beam to weld the base plate and reinforcing plate together.Type: GrantFiled: August 24, 2004Date of Patent: April 3, 2007Assignee: NHK Spring Co., Ltd.Inventors: Hideki Kashima, Itsuo Yasuda, Masato Kitakata, Yoichi Ikeji
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Patent number: 7132173Abstract: Braze and electrode wire assemblies, e.g., used with an implantable microstimulator, include a wire welded in the through-hole of an electrode, which electrode is brazed to a ceramic case that is brazed to a metal ring that is welded to a metal can. The braze joints are step or similar joints that self-center the case, provide lateral support during braze assembly, and provide increased surface area that prevents braze material from exuding from the joints. The end of the ceramic case that is brazed to the metal ring need not be specially machined. The shell has a reference electrode on one end and an active electrode on the other, and is externally coated on selected areas with conductive and non-conductive materials.Type: GrantFiled: June 27, 2003Date of Patent: November 7, 2006Assignee: Advanced Bionics CorporationInventor: Jay Daulton
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Patent number: 7115324Abstract: A method of joining metal components having the steps of depositing adhesive material between the components and welding the components together via solid-state or fusion welding. The welds are spaced apart from the adhesive material and are produced so as to prevent exposure of the adhesive material to the welding. The two types of bonds (adhesive and welding) are produced in the components separated by time and space.Type: GrantFiled: August 29, 2003Date of Patent: October 3, 2006Assignee: Alcoa Inc.Inventors: Israel Stol, Sherri F. McCleary, Paula L. Price
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Patent number: 7094834Abstract: A process for increasing the stress-cracking resistance of polystyrene molding compositions, stress-cracking-resistant, glossy polystyrene molding compositions, composite layered sheets or composite layered films with an outer layer of this type, and also processes for producing moldings for refrigeration equipment.Type: GrantFiled: July 16, 2002Date of Patent: August 22, 2006Assignee: BASF AktiengesellschaftInventors: Daniel Wagner, Peter Weinkötz, Herbert Morgenstern, Hans-Jürgen Renner
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Patent number: 7026056Abstract: A structure for encapsulating and protecting fiber insulation material as well as other materials in multicompartment devices in order to provide unitized material which can be applied to any surface desired for insulation or other purposes. A first sheet of material is formed with pockets or depressions in the sheet which are adapted for receiving the material desired to be unitized and a second sheet placed over the first sheet, and the two sheets are attached together in the areas between the pockets or depressions thus encapsulating the material in the pockets. The material is unitized by placing the material in individual sealed metal foil containers or compartments, then the individual containers of unitized material are attached in matrix form to a continuous sheet, such as positioning the containers in openings in the continuous sheet. The product can be applied to any surface desired for insulation or other purposes. Preferably a multilayer metal foil material is employed in the structures.Type: GrantFiled: October 13, 2004Date of Patent: April 11, 2006Assignee: ATD CorporationInventor: G. William Ragland
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Patent number: 6994916Abstract: The present invention provides an improved structural assembly constructed of a plurality of structural members secured together. At least one of the plurality of structural members defines a first region characterized by comparatively high operational stress and a second region having a locally refined grain structure positioned such that the second region at least partially encompasses the first region to thereby enhance the strength, toughness and fatigue resistance of the at least one structural member in the first region. The present invention also provides a method for selectively improving the strength, toughness and fatigue resistance of a structural member in a region of high operational stress including the steps of casting the structural member in a pre-selected configuration. Regions of the structural member having comparatively high operational stress are identified. The structural member is secured to prevent movement.Type: GrantFiled: February 8, 2002Date of Patent: February 7, 2006Assignee: The Boeing CompanyInventors: R. Scott Forrest, Douglas J. Waldron
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Patent number: 6872466Abstract: A method of plugging an area of damaged mesh in a sifting screen. The method is applicable to screens in which woven wire mesh is stretched, tensioned and secured over a supporting frame containing a plurality of windows and in which local damage to the mesh is in an area of the mesh which overlies one of the windows. The method has the steps of inserting into the window a device which is a close fit therein, and securing the device in the window so as to completely cover the area of damaged mesh. The device may be a former having stretched thereacross and secured thereto mesh similar to that stretched across the window in question, or simply a plate or block. The device may be secured in place by a force or interference fit, mechanical means, or adhesive, or the device may be resiliently deformable to allow it to be pushed past a projection in the window, so as to snap fit the device in place.Type: GrantFiled: July 8, 2002Date of Patent: March 29, 2005Assignee: United Wire LimitedInventors: Graham Robertson, Caspar Hassall
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Patent number: 6861156Abstract: A metal fiber-reinforced composite material can be produced by providing metal layers and reinforcing layers disposed alternately into a sandwich structure, the reinforcing layers containing fibers of a high-strength metallic material, which are disposed in the form of a loose structure between the metal layers, in order to create a material excess of fibers in the reinforcing layers, the sandwich structure being bonded by a thermomechanical process in such a manner, that the fibers are lengthened because of the excess of material, the sandwich structure being bonded.Type: GrantFiled: November 15, 2002Date of Patent: March 1, 2005Assignee: EADS Deutschland GmbHInventor: Frank Palm
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Publication number: 20040244157Abstract: This invention provides a fastener tape and a stinger for a slide fastener constituted of a warp knitting or weaving structure and including a tape main portion and a fastener element attaching portion, wherein a warp and a weft, which are composition yarns of the fastener tape, are composed of multifilament yarns and a size of a composition filament of the warp is 1.0 to 2.0 dTex, and a size of that of the weft is 2.0 to 5.0 dTex, these sizes of the single filaments being not larger than ¼ of the conventional composition filament, thereby achieving advantages that they adapt well to a fabric when and after a slide fastener is sewed to a thin fabric having flexibility and excellent drape performance and secure tape strength and coupling strength required as a slide fastener, the fastener tape and stringer ensuring flexibility and soft feeling.Type: ApplicationFiled: April 23, 2004Publication date: December 9, 2004Inventor: Yoshio Matsuda
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Patent number: 6824887Abstract: A structure for encapsulating and protecting fiber insulation material as well as other materials in multicompartment devices in order to provide unitized material which can be applied to any surface desired for insulation or other purposes. A first sheet of material is formed with pockets or depressions in the sheet which are adapted for receiving the material desired to be unitized and a second sheet placed over the first sheet, and the two sheets are attached together in the areas between the pockets or depressions thus encapsulating the material in the pockets. The material is unitized by placing the material in individual sealed metal foil containers or compartments, then the individual containers of unitized material are attached in matrix form to a continuous sheet, such as positioning the containers in openings in the continuous sheet. The product can be applied to any surface desired for insulation or other purposes. Preferably a multilayer metal foil material is employed in the structures.Type: GrantFiled: January 9, 2002Date of Patent: November 30, 2004Assignee: ATD CorporationInventor: G. William Ragland
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Patent number: 6821639Abstract: A wide sheet formed of a metal foil is wound a plurality of times around outer peripheral surfaces of four honeycomb matrices arranged in series to form an intermediate tube. As a result, a subassembly is formed. A brazing filler material is wound around an outer peripheral surface of the subassembly at an end portion thereof. The subassembly is inserted into an outer tube. The outer tube is caulked to reduce an outer diameter thereof. Then, heat processing is performed in vacuum to diffusion bond a corrugated sheet and a flat sheet, which form the honeycomb matrices, and the wide sheet of the intermediate tube to each other. The intermediate tube and the outer tube are brazed to each other. Thus, a metal substrate for carrying a catalyst is achieved.Type: GrantFiled: January 9, 2003Date of Patent: November 23, 2004Assignee: Calsonic Kansei CorporationInventor: Fumihiko Kato
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Patent number: 6821601Abstract: An improved stitchbonded fabric has a pattern of stitches formed by a multi-needle stitched set of contractible stitching threads in a planar material that comprises a non-fibrous layer of polymer or metal, such as a metallic foil, a polymeric film, or a leather. Contraction of the stitchbonded fabric provides the fabric with unusual tactile, visual and functional effects.Type: GrantFiled: July 12, 2001Date of Patent: November 23, 2004Assignee: Xymid, L.L.C.Inventors: Stephen Horace Tsiarkezos, Nicholas James Brownless
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Patent number: 6809305Abstract: Bonding of materials such as MEMS materials is carried out using microwaves. High microwave absorbing films are placed within a microwave cavity containing other less microwave absorbing materials, and excited to cause selective heating in the skin depth of the films. This causes heating in one place more than another. This thereby minimizes unwanted heating effects during the microwave bonding process.Type: GrantFiled: July 22, 2002Date of Patent: October 26, 2004Assignee: California Institute of TechnologyInventors: Martin B. Barmatz, John D. Mai, Henry W. Jackson, Nasser K. Budraa, William T. Pike
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Patent number: 6777106Abstract: The present invention is directed to a metal block suitable for machining, the metal block comprising at least two superimposed metal plates, each having a thickness of at least 12.5 mm, wherein the yield strength of the block is at least 75% of the yield strength of the initial metal plate(s). The present invention is further directed to methods for manufacturing such blocks from two or more thick metal plates by explosive welding and other methods. Blocks according to the present invention are useful, for example, for manufacturing aircraft structural components or injection molds for plastics or rubber.Type: GrantFiled: April 24, 2002Date of Patent: August 17, 2004Assignee: Pechiney RhenaluInventors: Frédéric Catteau, David Godard
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Publication number: 20040075300Abstract: In the present method for producing a planar element (2) for car bodies in sandwich construction, which includes an external skin (4) and a hump plate (6) having edge profiles (8, 10) arranged between them, in a first step the edge profiles (8, 10) are joined to the hump plate (6), at least partially using a mechanical joining method, in a second step the hump plate (6) is glued to the external skin (4), and in a third step the edge profiles (8, 10) are joined to the external skin (4), at least partially using a mechanical joining method. Through these measures, high shear and buckling resistance of the planar element is achieved.Type: ApplicationFiled: January 23, 2003Publication date: April 22, 2004Inventors: Hartmut Carstensen, Peter Buchwald, Fna Meyer
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Patent number: 6713190Abstract: A method is described for making a reinforcing wire frame for embedding in a moulded polymer support frame over which woven wire cloth is to be stretched and secured to form a sifting screen. The method involves locating lengths of cut wire substantially equally spaced apart in a jig to form a first array. A second array of lengths of cut wire is located over the first array with the lengths of wire in the second array being substantially at right angles to those of the first array. The lengths of wire in the first and second arrays are resistance welded at points of mutual intersection so as to form a first substantially rectilinear matrix.Type: GrantFiled: March 13, 2002Date of Patent: March 30, 2004Assignee: United Wire LimitedInventors: Gordon James Cook, Andrew Hughes, Arthur Robert Bailey, George Charles Hartnup, Dugald Stewart
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Patent number: 6709766Abstract: A method of manufacturing a structural assembly is provided. In one embodiment, the method includes the steps of providing first and second structural members having preselected shapes and dimensions. The first structural member defines a first raised portion and the second structural member defines a second raised portion. According to one embodiment, the providing step includes forming the first and second structural members into preselected shapes and dimensions. The first and second structural members can comprise plates, T-stiffeners or tubular members. The first raised portion of the first structural member is positioned adjacent to the second raised portion of the second structural member following the providing step to thereby define an interface therebetween and wherein the first and second raised portions define a substantially consumable weld land.Type: GrantFiled: September 20, 2002Date of Patent: March 23, 2004Assignee: The Boeing CompanyInventors: Gary W. Coleman, Terry L. Smith, Joseph Peter Reilley, Warner B. Vanaken, James H. Lee, Kevin L. Nash, Julius J. Schaan, Scott W. Franz
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Patent number: 6689471Abstract: A thermal management device includes anisotropic carbon encapsulated in an encapsulating material that is applied directly to the anisotropic carbon, wherein the anisotropic carbon includes graphite. An electrical system includes the thermal management device and electrical contacts and/or devices provided on the surface of the thermal management device. A method of fabricating a thermal management device includes cleaning a surface of anisotropic carbon, applying a coat of encapsulating material directly to the cleaned surface, and repeating the step of applying until the anisotropic carbon is encapsulated. Other embodiments of the invention are also described.Type: GrantFiled: January 2, 2003Date of Patent: February 10, 2004Assignees: Queen Mary and Westfield College, University of LondonInventors: Angelo Gandi, Rui De Oliveira, Anthony Arthur Carter
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Patent number: 6660403Abstract: A rigid structural foil and a method for forming a rigid structural foil is provided. The structural foil includes at least two layers of metal sheets, valley areas and spacers. The metal sheet layers include metal foil having a thickness of 0.006 in. The valley areas are disposed between compressed and uncompressed portions of the structural foil formed during compression of portions of the structural foil. In addition to the valley areas, the structural foil includes spacers. The spacers within the metal sheet layers provide spacing between portions of the metal layers such that the structural foil functions as both a heat shield and an acoustic shield.Type: GrantFiled: April 2, 2002Date of Patent: December 9, 2003Assignee: ATD CorporationInventors: G. William Ragland, Raymond E. Ragland, Christopher V. Ragland
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Patent number: 6660401Abstract: The present invention provides a solder disposed configuration for a heat resistant structure for forming a catalytic converter for purifying the exhaust gas in an engine. The heat resistant structure is composed of a honeycomb structure fitted and fixed into a hollow cylindrical shell. And the honeycomb structure comprises at least a substrate having a flat sheet and a corrugated sheet. A first and a second strip of solder are disposed alongside a first and a second edge paralleling to each other on a first and a second plane surface of the substrate respectively, wherein the second plane surface is the reverse side of the first plane surface of the substrate, and the first and second edge are opposite to each other on the first and the second plane surface respectively for forming the honeycomb structure. Rolling up the substrate to form the honeycomb structure (e.g. spirally wound-form) by the solder disposed on the substrate welded and joined together.Type: GrantFiled: December 20, 2001Date of Patent: December 9, 2003Inventor: Charles Hsu
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Patent number: 6659333Abstract: A metal foil connection of first and second metal foils having a thickness of less than 0.05 mm includes a connecting point in which the metal foils are brazed to one another. The connecting point forms a wedge which is filled with brazing medium. A mass of the brazing medium, and a mass of sections of the metal foils which the brazing medium contacts in the wedge, have a given ratio. A honeycomb body, a brazing medium particle fraction and a method for manufacturing metal foil connections with a thickness of less than 50 micrometers, are also provided.Type: GrantFiled: November 25, 2002Date of Patent: December 9, 2003Assignee: Emitec Gesellschaft fuer Emissionstechnologie mbHInventors: Ludwig Wieres, Ferdi Kurth, Helge Schlotmann
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Patent number: 6656603Abstract: A method of making an expanded metal sandwich structure includes cleaning at least two metal superplastic core sheets to remove metal oxides and residues that would interfere with diffusion bonding of the sheets. The core sheets are placed face-to-face and a gas pressure line fitting is inserted between one edge and is welded into place. The fitting has a through bore through which gas can flow under pressure from a gas pressure control system into the space between the core sheets. The core sheets are pressed together and laser welded together into a core pack along lines which will form junction lines between the core sheets when the core pack is superplastically expanded. The core pack is chemically cleaned to remove metal oxides and residues that would interfere with diffusion bonding of the core pack sheets to face sheets. Two metal face sheets having superplastic characteristics are chemically cleaned and placed over and under the core pack.Type: GrantFiled: June 6, 2002Date of Patent: December 2, 2003Assignee: The Boeing CompanyInventors: Frederick W. Buldhaupt, David H. Gane, Matthew G. Kistner, Jeffrey D. Will
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Patent number: 6638641Abstract: A joining process and friction welded structure is disclosed, including a first member with a conoid recess, and a second member with a second conoid tip that is friction welded to the recess in the first member. One, or both, of the conoids may be a non-spheroid, such as a paraboloid. In addition, the conoid recess may have a vertex angle that is greater than a vertex angle of the conoid tip.Type: GrantFiled: October 10, 2001Date of Patent: October 28, 2003Assignee: Agilent Technologies, Inc.Inventor: Andrew Douglas Delano
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Patent number: 6638639Abstract: High efficiency, thin-walled turbine components such as turbine blade airfoils comprise a superalloy substrate covered by a thin skin. The thin skin may be bonded to the inner spar structure of a turbine blade airfoil by a transient liquid phase bonding process. The inner spar preferably comprises a cast single crystal nickel base superalloy. The thin skin may comprise a single crystal or polycrystalline nickel base superalloy or the like.Type: GrantFiled: July 6, 2000Date of Patent: October 28, 2003Assignee: Siemens Westinghouse Power CorporationInventors: Michael A. Burke, Paula D. Freyer, Mohan A. Hebbar, Brij B. Seth, Gary W. Swartzbeck, Thomas Walter Zagar
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Patent number: 6638640Abstract: A multi-layered metal plate with excellent damping capacity and particularly, to a multi-layered metal plate with excellent damping capacity and a method for manufacturing it, is less costly since the plate can be simply manufactured by simply attaching a thin plate on a main metal plate by the methods such as welding and the like, has excellent damping capacity and especially can be easily shaped. In addition, in the plate, the secondary plate is attached on one or both surfaces of the main metal plate.Type: GrantFiled: April 9, 2002Date of Patent: October 28, 2003Assignee: Korea Institute of Science and TechnologyInventor: Kwang-Koo Jee
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Patent number: 6630249Abstract: A composite structural laminate plate suitable for building maritime vessels or for building civil structures such as double hull oil tankers, bulk carriers, barges decks for roll-on roll-off ferries, orthotropic bridge decks or for building any structural application in which the traditional method of construction uses stiffened steel plates. The laminate has two facing metal layers that are structurally bonded to a polyurethane elastomer core which may have steel or rigid foam void sections embedded within. The laminate provides equivalent inplane and transverse stiffness and strength, reduces fatigue problems, minimizes stress concentrations, improves thermal and acoustical insulation, and provides vibration control. The laminate provides a structural system that acts as a crack arrest layer and that can join two dissimilar metals without welding or without setting up a galvanic cell.Type: GrantFiled: May 11, 2001Date of Patent: October 7, 2003Assignee: Fern Investments LimitedInventor: Stephen J. Kennedy
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Patent number: RE38852Abstract: A tear/puncture resistant semi-laminate material having a first layer of a flexible sheet of thermoplastic material and a second layer of a water impermeable thermoplastic material impregnated with a volatile corrosion inhibitor. The layers are not bonded with a uniform layer of adhesive, but are semi-laminated by bonding at points or in strips at the edges of the respective layers or at discrete, discontinuous intervals across the width of the material. In the preferred embodiments, the first layer is a tear resistant layer, which may be a layer of woven fibers, a nonwoven layer of spunbonded fibers, or a tear resistant film. In an alternative embodiment, polypropylene is substituted for polyethylene in the first and second layers.Type: GrantFiled: May 2, 2003Date of Patent: October 25, 2005Inventor: Victor Manuel Quinones