公开(公告)号：US20250122595A1

公开(公告)日：2025-04-17

申请号：US18486468

申请日：2023-10-13

Applicant: GM Global Technology Operations LLC

Inventor： Qigui Wang ,  Yi Liu ,  Ronald C. Daul ,  Ali Shabbir ,  Kestutis A. Sonta ,  Daniel J. Wilson

IPC: C22C1/10 ,  B33Y80/00 ,  C01B32/19 ,  C22C9/00

Abstract: Systems, methods, and devices for forming and implementing a graphene-copper composite powder are disclosed. The graphene-copper composite powder may be formed by providing an inert environment, introducing a first mist to the inert environment, introducing a second mist to the inert environment, and mixing the first mist and the second mist within the inert environment to thereby produce a graphene-copper composite powder. The first mist being atomized copper with a negative charge, and the second mist including graphene flakes with a positive charge. The graphene-copper composite powder may be used to form components via additive manufacturing or traditional powder metallurgy processes.

公开(公告)号：US20240131570A1

公开(公告)日：2024-04-25

申请号：US17969808

申请日：2022-10-19

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Andrew Thomas Cunningham ,  Ali Shabbir ,  Hassan Ajami ,  Ibrahim El Khatib

IPC: B21D37/04 ,  B21D37/14

CPC classification number: B21D37/04 ,  B21D37/14 ,  B33Y80/00

Abstract: Presented are hybrid fixture assemblies with integrated additive manufactured features, methods for making/using such fixtures, and manufacturing systems equipped with such fixtures. A manufacturing fixture assembly includes a fixture support frame formed, at least in part, from a first material, and a fixture support shell formed, at least in part, from a second material distinct from the first material. The support frame, which seats on/mounts to a work surface, includes a skeletal substructure with multiple male connectors projecting therefrom. The skeletal substructure contains multiple first frame walls that are removably intermeshed with multiple second frame walls in a collapsible format. The support shell includes a support surface that holds a workpiece, an interface surface that abuts the skeletal substructure, and multiple female connectors that project from the interface surface. Each female connector removably receives therein a respective male connector to thereby detachably mount the support shell to the support frame.

公开(公告)号：US20250167339A1

公开(公告)日：2025-05-22

申请号：US18513746

申请日：2023-11-20

Applicant: GM Global Technology Operations LLC

Inventor： Yi Liu ,  Qigui Wang ,  Kestutis A. Sonta ,  Ronald C. Daul ,  Ali Shabbir

IPC: H01M10/6554 ,  H01M10/613 ,  H01M10/625 ,  H01M10/647 ,  H01M10/6568

Abstract: A battery pack assembly includes a battery pack enclosure, a first cooling plate, a plurality of battery cells, and a plurality of second cooling plates. The first cooling plate is supported by the floor within the battery pack enclosure, and the first cooling plate is formed of graphene aluminum composite. The plurality of battery cells is supported by the first cooling plate, and the first cooling plate is disposed between the floor of the battery pack enclosure and the plurality of battery cells. The second cooling plates are disposed between each of the battery cells, and the second cooling plates are formed from graphene aluminum composite.

公开(公告)号：US20230356293A1

公开(公告)日：2023-11-09

申请号：US17735337

申请日：2022-05-03

Applicant: GM Global Technology Operations LLC

Inventor： Daniel J. Wilson ,  Liang Wang ,  Qigui Wang ,  Devin R. Hess ,  Michelle A. Wood ,  Ronald C. Daul ,  Ali Shabbir

IPC: B22D17/22 ,  B22C9/22

CPC classification number: B22D17/229 ,  B22C9/22

Abstract: A design for repair casting having a repairable ultra-large single-piece casting and a replacement part. The ultra-large single-piece casting includes a main body portion, at least one predefined replaceable portion integrally cast with the main body portion, and a cut-guide delineating the predefined replaceable portion from the main body portion. The cut-guide includes a continuous channel defined on an exterior surface of the single-piece casting. The cut-guide further includes a rib extending from a channel wall on the main body portion. A damaged replaceable portion is excisable from the main-body portion by cutting through the single-piece casting along the cut-guide. The excised damaged replaceable portion may be replaced with the replacement part, which has substantially the same geometry, dimensions, and mechanical properties as an undamaged replaceable portion. The replacement part may be joined to the main body portion by mechanical means or by welding.

公开(公告)号：US11359522B2

公开(公告)日：2022-06-14

申请号：US16450306

申请日：2019-06-24

Applicant: GM Global Technology Operations LLC

Inventor： Andrew Thomas Cunningham ,  Andrea Boscolo ,  Ali Shabbir ,  Zachary P. Steffes ,  Michael P. Van De Velde

IPC: F01L1/14 ,  F01M9/10 ,  F01L1/46

Abstract: A tubular structure comprises a first end and a second end, a cylindrical outer structure, and at least one inner cavity defined by the cylindrical outer structure and the first and second ends. The first and second ends each include a recess and a cap press fit within the recess. The caps provide a connection point for the ends of the tubular structure. Each end includes a vent in fluid communication with the inner cavity during manufacturing of the tubular structure, prior to insertion of the caps. An isotropic internal support structure extends longitudinally between the ends within the cylindrical outer structure and defines an oil flow channel extending through the tubular structure, each cap includes a cap orifice aligned with the oil flow channel, and the cylindrical outer structure, the first and second ends, and the internal support structure are continuously and unitarily formed.

公开(公告)号：US20220088671A1

公开(公告)日：2022-03-24

申请号：US17024919

申请日：2020-09-18

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Dale A. Gerard ,  Qigui Wang ,  Tyson W. Brown ,  Ali Shabbir ,  Anil K. Sachdev

IPC: B22C9/10 ,  B22C1/18 ,  B22D17/22

Abstract: A high heat-absorption casting core for manufacturing a cast component includes a core body. The core body has at least a portion thereof defined by metal powder. The metal powder is configured to absorb heat energy from the cast component during cooling of the component and solidification thereof. The core body may be additionally defined by a sand fraction in contact with the metal powder fraction. A system and a method for manufacturing a cast component using the high heat-absorption casting core are also envisioned.

公开(公告)号：US20240042496A1

公开(公告)日：2024-02-08

申请号：US17817314

申请日：2022-08-03

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Stanley Tong ,  Jeffrey B Harris ,  Brennon L White ,  Adam John Campbell ,  Andrew Thomas Cunningham ,  Ali Shabbir

IPC: B08B5/04 ,  B25J11/00

CPC classification number: B08B5/04 ,  B25J11/0085

Abstract: Systems and methods are provided for cleaning surfaces of a workpiece. The system includes a housing defining an enclosure, a holding structure within the enclosure that is configured to support a workpiece, a first powder removal device that is configured to propel a first media toward the holding structure such that the first media contacts the workpiece while the workpiece is supported by the holding structure, a first sensing device that is configured to detect surface characteristics of the workpiece while the workpiece is supported by the holding structure, and a controller configured to, by a processor: detect a powder material on a surface of the workpiece based on the surface characteristics, and selectively operate the first powder removal device to remove the powder material from the surface with the first media while the workpiece is supported by the holding structure.

公开(公告)号：US20210213706A1

公开(公告)日：2021-07-15

申请号：US16739523

申请日：2020-01-10

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Reza Bihamta ,  Ali Shabbir

IPC: B32B7/12 ,  B29C64/147

Abstract: A hybrid part includes a base structure and a plurality of layers of additive manufacturing material disposed on and attached to the base structure. The base structure may includes a plurality of sheets of base material, and/or a base formed by any non-additive manufacturing method. A method of forming a hybrid part includes providing a base structure that includes either or both of: a) a plurality of sheets of base material, and b) a base formed by a non-additive method. The method further includes disposing a plurality of layers of additive manufacturing material, layer by layer, onto the base structure.

公开(公告)号：US20200298472A1

公开(公告)日：2020-09-24

申请号：US16361685

申请日：2019-03-22

Applicant: GM Global Technology Operations LLC

Inventor： Andrew Thomas Cunningham ,  Brennon L. White ,  Paul J. Wolcott ,  Ali Shabbir ,  Zachary P. Steffes

IPC: B29C64/147 ,  B29C64/20 ,  B29C64/393

Abstract: An additive manufacturing method comprises: positioning a sheet of composite material; curing a predetermined portion of the sheet; cutting the sheet about the perimeter of the predetermined portion to create a preceding processed sheet; adding a successive sheet of composite material atop and in contact with the preceding processed sheet; curing a predetermined portion of the successive sheet such that the predetermined portions of the successive sheet and the preceding processed sheet are bonded together; and cutting the successive sheet about the perimeter of its predetermined portion to create a subsequent processed sheet. The steps of adding, curing and cutting a successive sheet may be repeated for a plurality of cycles to produce a three-dimensional composite product.

公开(公告)号：US20180031065A1

公开(公告)日：2018-02-01

申请号：US15220829

申请日：2016-07-27

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Ali Shabbir ,  David Begleiter

IPC: F16D66/02

CPC classification number: F16D66/021 ,  F16D55/225 ,  F16D66/026

Abstract: An electromechanical brake system capable of conducting a brake pad wear check includes a structure defining a chamber, a member that rotates with a wheel, a motor mounted to the structure, a reciprocating piston, a brake pad, and a controller. The piston is driven by the motor between a variable actuated position and a retracted position. The brake pad is movably supported by the structure, operatively coupled to the piston, and adapted for braking contact with the member when the piston is in the actuated position, and spaced from the member when the piston is in the retracted position. The controller controls reciprocation of the piston between the actuated and retracted positions via energization of the motor, performs a brake pad wear check by calculating a change in a parameter associated with a change in distance between positions, and compares the change in parameter to a threshold value.