Patents by Inventor Andrew E. Modin
Andrew E. Modin 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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Publication number: 20230415432Abstract: An example method of forming a composite structure is described that includes applying a laminated charge onto an expandable pallet, moving the expandable pallet at a translation rate and relative to a die conveyor that comprises a plurality of die sections, and driving the plurality of die sections on the die conveyor at an angle relative to the expandable pallet so as to drive the plurality of die sections progressively deeper into a recess defined by the expandable pallet and shape the laminated charge into at least part of a shape of the composite structure.Type: ApplicationFiled: September 11, 2023Publication date: December 28, 2023Inventors: Richard A. Prause, Allen Halbritter, Andrew E. Modin
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Patent number: 11806949Abstract: A bladder mandrel package, used to manufacture a composite structure, includes a mandrel and a wrap ply, surrounding the mandrel to form a wrapped mandrel. The bladder mandrel package also includes a first radius filler, coupled to the wrap ply at a first radius of the wrapped mandrel, and a second radius filler coupled to the wrap ply at a second radius of the wrapped mandrel. The mandrel, the wrap ply, the first radius filler, and the second radius filler are consolidated to from the bladder mandrel package.Type: GrantFiled: October 20, 2021Date of Patent: November 7, 2023Assignee: The Boeing CompanyInventors: Richard A. Prause, Andrew E. Modin, Allen J. Halbritter, Richard E. Heath
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Patent number: 11787133Abstract: An example method of forming a composite structure is described that includes applying a laminated charge onto an expandable pallet, moving the expandable pallet at a translation rate and relative to a die conveyor that comprises a plurality of die sections, and driving the plurality of die sections on the die conveyor at an angle relative to the expandable pallet so as to drive the plurality of die sections progressively deeper into a recess defined by the expandable pallet and shape the laminated charge into at least part of a shape of the composite structure.Type: GrantFiled: January 25, 2022Date of Patent: October 17, 2023Assignee: The Boeing CompanyInventors: Richard A. Prause, Allen Halbritter, Andrew E. Modin
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Patent number: 11766840Abstract: There is provided a forming apparatus for forming a high contour composite structure. The forming apparatus includes an upper die and a lower die between which a composite charge is formed. The forming apparatus further includes a plurality of load cells, a control system, and an overlay tool assembly coupled to the upper die. The overlay tool assembly has scalloped sections positioned between pairs of the plurality of load cells, and positioned against portion(s) of the composite charge. The composite charge has ply discontinuity features through the one or more portions. The overlay tool assembly denies pressure and a through thickness compaction to the one or more portions of the composite charge during a forming process, to allow one or more plies in the one or more portions to move after the forming process, and to enable in-plane bending of the high contour composite structure in post-forming operations.Type: GrantFiled: August 30, 2021Date of Patent: September 26, 2023Assignee: The Boeing CompanyInventors: James R. Kendall, Raviendra S. Suriyaarachchi, Andrew E. Modin
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Publication number: 20230234307Abstract: An example method of forming a composite structure is described that includes applying a laminated charge onto an expandable pallet, moving the expandable pallet at a translation rate and relative to a die conveyor that comprises a plurality of die sections, and driving the plurality of die sections on the die conveyor at an angle relative to the expandable pallet so as to drive the plurality of die sections progressively deeper into a recess defined by the expandable pallet and shape the laminated charge into at least part of a shape of the composite structure.Type: ApplicationFiled: January 25, 2022Publication date: July 27, 2023Inventors: Richard A. Prause, Allen Halbritter, Andrew E. Modin
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Patent number: 11697255Abstract: A ply transporting and compacting apparatus comprises a rigid frame, a top-layer sheet of flexible rubber material fastened to the frame, and a bottom-layer sheet of perforated flexible rubber material having openings. The apparatus also comprises a middle-layer sheet of flow media material disposed in a first plenum area that is defined between the top and bottom layer sheets. The apparatus further comprises a moving device coupled to the frame and arranged to lower the frame and sheets onto a composite ply at a trimming location to pick up the composite ply with a suction force when a vacuum is drawn in the first plenum area to create the suction force through the openings of the bottom-layer sheet.Type: GrantFiled: March 2, 2022Date of Patent: July 11, 2023Assignee: The Boeing CompanyInventors: Richard A. Prause, Allen J. Halbritter, Andrew E. Modin
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Patent number: 11685082Abstract: Described herein are methods and systems for forming composite stringer assemblies or, more specifically, for shaping composite charges while forming these stringer assemblies. A system comprises a bladder, having a bladder core, and a bladder skin. The bladder core is formed from foam. The bladder skin is formed from an elastic material and encloses the bladder core. When a composite stringer assembly is formed, the bladder is positioned over a charge base. The charge base later becomes a stringer base, such as a fuselage section or a wing skin. A charge hat is then positioned over the bladder and is conformed to the bladder. A combination of the bladder skin and the bladder core provides support during this forming operation and later while the stringer assembly is cured. In some examples, the bladder core is collapsible for the removal of the bladder from the cavity of the stringer assembly.Type: GrantFiled: September 3, 2021Date of Patent: June 27, 2023Assignee: The Boeing CompanyInventors: Richard Alexander Prause, Richard E. Heath, Andrew E. Modin, Byron James Autry, Ivan Gilberto Ramirez
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Publication number: 20230063884Abstract: There is provided a forming apparatus for forming a high contour composite structure. The forming apparatus includes an upper die and a lower die between which a composite charge is formed. The forming apparatus further includes a plurality of load cells, a control system, and an overlay tool assembly coupled to the upper die. The overlay tool assembly has scalloped sections positioned between pairs of the plurality of load cells, and positioned against portion(s) of the composite charge. The composite charge has ply discontinuity features through the one or more portions. The overlay tool assembly denies pressure and a through thickness compaction to the one or more portions of the composite charge during a forming process, to allow one or more plies in the one or more portions to move after the forming process, and to enable in-plane bending of the high contour composite structure in post-forming operations.Type: ApplicationFiled: August 30, 2021Publication date: March 2, 2023Inventors: James R. Kendall, Raviendra S. Suriyaarachchi, Andrew E. Modin
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Patent number: 11534989Abstract: A forming module for forming a composite laminate part over a tool is provided. The forming module comprises a base, a ply carrier control assembly adapted for controlling the position of a flexible ply carrier on which composite resin plies are mounted, and a head section mounted on the base and adapted for automatically forming the composite resin plies from the ply carrier onto the tool.Type: GrantFiled: October 11, 2019Date of Patent: December 27, 2022Assignee: The Boeing CompanyInventors: James N. Buttrick, Dennis Wayne Stewart, Andrew E. Modin, David Paul Banks, Edoardo Depase, Jesus Sanchez
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Publication number: 20220388256Abstract: An example method of forming a composite structure includes applying a laminated charge onto an expandable pallet, moving the expandable pallet in a linear motion relative to a plurality of rollers, and progressively urging the laminated charge into a continuously expanding recess defined by the expandable pallet using the plurality of rollers. The plurality of rollers are oriented in a serial configuration so as to shape the laminated charge into at least part of a shape of the composite structure.Type: ApplicationFiled: March 17, 2022Publication date: December 8, 2022Inventors: Richard A. Prause, Andrew E. Modin, Allen Halbritter, Richard E. Heath, Ivan G. Ramirez, John R. Nibe
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Publication number: 20220184902Abstract: A ply transporting and compacting apparatus comprises a rigid frame, a top-layer sheet of flexible rubber material fastened to the frame, and a bottom-layer sheet of perforated flexible rubber material having openings. The apparatus also comprises a middle-layer sheet of flow media material disposed in a first plenum area that is defined between the top and bottom layer sheets. The apparatus further comprises a moving device coupled to the frame and arranged to lower the frame and sheets onto a composite ply at a trimming location to pick up the composite ply with a suction force when a vacuum is drawn in the first plenum area to create the suction force through the openings of the bottom-layer sheet.Type: ApplicationFiled: March 2, 2022Publication date: June 16, 2022Applicant: The Boeing CompanyInventors: Richard A. Prause, Allen J. Halbritter, Andrew E. Modin
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Publication number: 20220143938Abstract: There is provided a forming apparatus for constraining a composite charge and forming the composite charge into a highly contoured composite structure. The forming apparatus includes a first die and a second die between which the composite charge is formed. The first die has pairs of first die portions spaced apart to define a die cavity into which the composite charge is formed into a contoured hat section having a cap. The forming apparatus includes a constraining assembly having a constraining device positioned in the die cavity. The constraining device is designed to constrain a cap portion, and to apply an upward resistive force against the cap portion, and against a downward compressive force applied by the second die, to provide wrinkle prevention in the cap as the contoured hat section is formed. The constraining assembly has a retaining element to retain the constraining device.Type: ApplicationFiled: October 15, 2021Publication date: May 12, 2022Inventors: Richard E. Heath, Andrew E. Modin, Richard A. Prause, Paul D. Shaw, Raviendra S. Suriyaarachchi
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Publication number: 20220134610Abstract: Described herein are methods and systems for forming composite stringer assemblies or, more specifically, for shaping composite charges while forming these stringer assemblies. A system comprises a bladder, having a bladder core, and a bladder skin. The bladder core is formed from foam. The bladder skin is formed from an elastic material and encloses the bladder core. When a composite stringer assembly is formed, the bladder is positioned over a charge base. The charge base later becomes a stringer base, such as a fuselage section or a wing skin. A charge hat is then positioned over the bladder and is conformed to the bladder. A combination of the bladder skin and the bladder core provides support during this forming operation and later while the stringer assembly is cured. In some examples, the bladder core is collapsible for the removal of the bladder from the cavity of the stringer assembly.Type: ApplicationFiled: September 3, 2021Publication date: May 5, 2022Applicant: The Boeing CompanyInventors: Richard Alexander Prause, Richard E. Heath, Andrew E. Modin, Byron James Autry, Ivan Gilberto Ramirez
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Patent number: 11318689Abstract: A ply transporting and compacting apparatus comprises a rigid frame, a top-layer sheet of flexible rubber material fastened to the frame, and a bottom-layer sheet of perforated flexible rubber material having openings. The apparatus also comprises a middle-layer sheet of flow media material disposed in a first plenum area that is defined between the top and bottom layer sheets. The apparatus further comprises a moving device coupled to the frame and arranged to lower the frame and sheets onto a composite ply at a trimming location to pick up the composite ply with a suction force when a vacuum is drawn in the first plenum area to create the suction force through the openings of the bottom-layer sheet.Type: GrantFiled: December 21, 2018Date of Patent: May 3, 2022Assignee: The Boeing CompanyInventors: Richard A. Prause, Allen J. Halbritter, Andrew E. Modin
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Publication number: 20220118720Abstract: A method of forming a composite part from a mufti-ply prepreg composite charge comprises reducing pressure inside a bladder, located in a chamber that is at atmospheric pressure, below the atmospheric pressure. The method also comprises placing the multi-ply prepreg composite charge, having a first shape, in the chamber and reducing pressure inside the chamber below the atmospheric pressure. The method additionally comprises, while maintaining pressure inside the chamber below the atmospheric pressure, expanding the bladder within the chamber by increasing pressure inside the bladder to the atmospheric pressure, so that the multi-ply prepreg composite charge is compressed between the bladder and a forming tool, which is located inside the chamber, and the multi-ply prepreg composite charge is configured by the forming tool to a second shape, different from the first shape. The method also comprises curing the multi-ply prepreg composite charge, having the second shape.Type: ApplicationFiled: July 23, 2021Publication date: April 21, 2022Applicant: The Boeing CompanyInventors: Andrew E. Modin, Dorekia Martin, Richard E. Heath, Eric C. Anderson, Caleb J. Handolescu, Richard Alexander Prause, Michael C. Hargrove, Justin H. Register
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Patent number: 11305498Abstract: A method is provided for fabricating a composite ply layup with a desired shape. The method includes moving a shuttle having a sheet of elastic material into engagement with at least one composite ply at a ply pickup station, and picking up the at least one composite ply with the shuttle. The method also includes transporting the shuttle and the at least one composite ply from the ply pickup station to a forming station, and moving the shuttle and the at least one composite ply into engagement with a forming tool at the forming station or any previously laid plies on the forming tool. The method further includes compacting the at least one composite ply on the forming tool or any previously laid plies on the forming tool with the shuttle to form the composite ply layup with the desired shape.Type: GrantFiled: December 21, 2018Date of Patent: April 19, 2022Assignee: The Boeing CompanyInventors: Richard A. Prause, Andrew E. Modin
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Publication number: 20220040938Abstract: A bladder mandrel package, used to manufacture a composite structure, includes a mandrel and a wrap ply, surrounding the mandrel to form a wrapped mandrel. The bladder mandrel package also includes a first radius filler, coupled to the wrap ply at a first radius of the wrapped mandrel, and a second radius filler coupled to the wrap ply at a second radius of the wrapped mandrel. The mandrel, the wrap ply, the first radius filler, and the second radius filler are consolidated to from the bladder mandrel package.Type: ApplicationFiled: October 20, 2021Publication date: February 10, 2022Applicant: The Boeing CompanyInventors: Richard A. Prause, Andrew E. Modin, Allen J. Halbritter, Richard E. Heath
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Patent number: 11214021Abstract: A method for manufacturing a cured composite structure from first stringers, second stringers and a panel comprising a first side and a second side, the method includes, for each first stringer, supporting the first stringer on the first side of the panel using a substantially rigid mandrel positioned within a first cavity defined between the first stringer and the first side of the panel, for each second stringer, supporting the second stringer on the second side of the panel using a flexible mandrel positioned within a second cavity defined between the second stringer and the second side of the panel, and co-curing the first stringers, the panel, and the second stringers while each of the one or more first stringers are supported by the respective substantially rigid mandrel and each of the one or more second stringers are supported by the respective flexible mandrel.Type: GrantFiled: March 6, 2020Date of Patent: January 4, 2022Assignee: The Boeing CompanyInventors: Richard E. Heath, Richard A. Prause, Andrew E. Modin
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Patent number: 11179902Abstract: A bladder mandrel package, used to manufacture a composite structure, includes a mandrel and a wrap ply, surrounding the mandrel to form a wrapped mandrel. The bladder mandrel package also includes a first radius filler, coupled to the wrap ply at a first radius of the wrapped mandrel, and a second radius filler coupled to the wrap ply at a second radius of the wrapped mandrel. The mandrel, the wrap ply, the first radius filler, and the second radius filler are consolidated to from the bladder mandrel package.Type: GrantFiled: December 19, 2018Date of Patent: November 23, 2021Assignee: The Boeing CompanyInventors: Richard A. Prause, Andrew E. Modin, Allen J. Halbritter, Richard E. Heath
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Publication number: 20210276285Abstract: A method for manufacturing a cured composite structure from first stringers, second stringers and a panel comprising a first side and a second side, the method includes, for each first stringer, supporting the first stringer on the first side of the panel using a substantially rigid mandrel positioned within a first cavity defined between the first stringer and the first side of the panel, for each second stringer, supporting the second stringer on the second side of the panel using a flexible mandrel positioned within a second cavity defined between the second stringer and the second side of the panel, and co-curing the first stringers, the panel, and the second stringers while each of the one or more first stringers are supported by the respective substantially rigid mandrel and each of the one or more second stringers are supported by the respective flexible mandrel.Type: ApplicationFiled: March 6, 2020Publication date: September 9, 2021Applicant: The Boeing CompanyInventors: Richard E. Heath, Richard A. Prause, Andrew E. Modin