Leon M Headings

20210268769, Sep 2, 2021

Sep 11, 2020

17/018289

- Tokyo, JP
- Columbus OH, US
Mark Bryant Gingerich - Columbus OH, US
Leon M. Headings - Hilliard OH, US

B32B 7/08
B32B 15/01
B32B 37/00

A composite component includes a reinforcement bonded to a base component by a bond formed by, or reinforced with, a localized coupling in the base component. The bond may be formed by ultrasonic additive manufacturing. The localized coupling may include a compression of the base component, a weld in the base component, or a heat affected zone of the weld. Where the bond is formed by the localized coupling, the localized coupling encompasses the reinforcement. Where the bond is reinforced with the localized coupling, the localized coupling may encompass the reinforcement, or be arranged at an inside radius of a turn in the reinforcement. The reinforcement results in the composite component having enhanced properties such as lower density, increased strength, stiffness, or energy absorption capabilities.

20210069788, Mar 11, 2021

Sep 10, 2020

17/016893

- Columbus OH, US
Marcelo J. Dapino - Columbus OH, US
Leon M. Headings - Columbus OH, US
Mark Bryant Gingerich - Columbus OH, US
Jennifer L. Morris - Columbus OH, US

B22F 3/105
B23K 20/10
A61M 25/00

Various implementations include a method of manufacturing one or more devices. The method includes obtaining a base portion of a non-shape-memory metal, disposing one or more shape-memory metal portions along the base portion, and joining at least a first layer of the non-shape-memory metal to the base portion using ultrasonic additive manufacturing. The shape-memory metal portions are disposed along a first base surface of the base portion. The shape-memory metal portions have a first portion contacting the base portion and a second portion spaced apart from the first portion and extending from the base portion. The first layer is joined to the base portion using ultrasonic additive manufacturing and has a first layer surface that is joined to the first base surface. The first layer surface contacts the shape-memory metal portions when the first layer is joined to the base portion.

20210069822, Mar 11, 2021

Sep 4, 2020

17/013128

- Columbus OH, US
Leon Headings - Columbus OH, US
Mark Gingerich - Columbus OH, US

B23K 20/10
B23P 6/00

An ultrasonic additive manufacturing system may include a base structure, a sonotrode configured to rotate about an axis of rotation, and one or more transducers configured to vibrate the sonotrode. The sonotrode may include a welding surface extending along a circumference of the sonotrode, and the welding surface may have a contoured profile. At least one of the sonotrode and the base structure may be configured to translate relative to the other of the sonotrode and the base structure.

20210039190, Feb 11, 2021

Oct 13, 2020

17/069607

- Tokyo, JP
- Columbus OH, US
Allen Sheldon - Raymond OH, US
Marcelo Dapino - Columbus OH, US
Mark Bryant Gingerich - Columbus OH, US
Matthew Scheidt - Columbus OH, US
Leon Headings - Columbus OH, US

B23K 11/16
B23K 11/11

A transition structure includes a metallic portion, a fiber portion including a plurality of tows embedded within the metallic portion and extending out from the metallic portion forming a fabric, and a binding material forming a matrix surrounding the fiber portion embedded within the metallic portion. The fiber portion may be attached to or form part of a composite vehicle component. The transition structure may join a metallic component and a composite component. The transition structure may be manufactured by creating first channels within a layer of a metallic substrate, inserting fiber tows into the first channels, placing a first metallic layer over the metallic substrate and the fiber tows, consolidating the metallic layer to the metallic substrate, and binding the fiber tows within a resin. Prior to binding, additional layers of channels and fiber tows may be consolidated onto the first metallic layer.

20200139482, May 7, 2020

Jan 8, 2020

16/737234

- Tokyo, JP
- Columbus OH, US
Leon M. Headings - Columbus OH, US
Mark Bryant Gingerich - Columbus OH, US

B23K 11/20
B23K 11/11
B23K 20/10
B62D 27/02
B62D 25/20
B62D 25/06
B62D 25/02

A vehicle body assembly is described herein, including a first structural component and a second structural component. The first structural component may be a roof component or a side panel, and include a first part including a first metal and a second part including a second metal different than the first metal. The second part is formed on a peripheral edge portion of the first part and defines a mounting flange for the first structural component. The second part is joined to the first part via an ultrasonic additive manufacturing (UAM) interface. The second structural component is including the second metal and is joined to the second part at the mounting flange via a resistance spot weld (RSW) joint.

20190358739, Nov 28, 2019

Oct 10, 2018

16/156532

- Tokyo, JP
- Columbus OH, US
Leon HEADINGS - Columbus OH, US
Mark Bryant GINGERICH - Columbus OH, US

B23K 20/10
B23K 20/26
B23K 37/04

According to one aspect, the present disclosure provides a system for manufacturing transition structures including fiber threads embedded within a metal component. The system may include a supply of base sheet metal. The system may include a conveyor supported on a plurality of rollers and configured to move the base sheet metal in a production direction. The system may include a plurality of stages arranged in the production direction. Each stage may include a channel forming device configured to form a channel in the base sheet metal, a fiber inserting device configured to insert a portion of a fiber material into the channel, and one or more ultrasonic welders configured to consolidate a layer of metal foil over the fiber. The disclosure includes methods of using the system to produce transition structures and reinforced components.

20190210657, Jul 11, 2019

Jan 11, 2018

15/867930

- Columbus OH, US
Marcelo J. Dapino - Columbus OH, US
Venkata Siva C. Chillara - Columbus OH, US
Leon M. Headings - Columbus OH, US

B62D 25/18
B62D 37/02
B62D 25/16
B62D 35/00

A morphing fender skirt includes a rigid, open-ended arched base, stretchable exterior skin connected across the base, and a structural, bendable rib array connected over the base subjacent to the skin. The rib array is configured to bend between a flattened shape over the base, whereby the rib array imparts the flattened shape to the skin across the base, and a domed shape over the base, whereby the rib array imparts the domed shape to the skin across the base.

20190061042, Feb 28, 2019

Aug 29, 2017

15/689095

- Tokyo, JP
- Columbus OH, US
Leon M. Headings - Columbus OH, US
Mark Bryant Gingerich - Columbus OH, US

B23K 11/20
B62D 25/02
B62D 25/06
B62D 25/20
B62D 27/02
B62D 29/00
B23K 20/10
B23K 11/11

A vehicle body assembly is described herein, including a first structural component and a second structural component. The first structural component may be a roof component or a side panel, and include a first part including a first metal and a second part including a second metal different than the first metal. The second part is formed on a peripheral edge portion of the first part and defines a mounting flange for the first structural component. The second part is joined to the first part via an ultrasonic additive manufacturing (UAM) interface. The second structural component is including the second metal and is joined to the second part at the mounting flange via a resistance spot weld (RSW) joint.