Patents by Inventor Carey E. Wilkinson
Carey E. Wilkinson 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: 20200282698Abstract: A panel comprises a first face sheet and a second face sheet spaced apart from the first face sheet. The panel further comprises a core sheet intercoupled between the first face sheet and the second face sheet. Each of the first and second face sheets is made of a material having a thermal expansion that is different from the thermal expansion of the other face sheet.Type: ApplicationFiled: January 22, 2020Publication date: September 10, 2020Applicant: The Boeing CompanyInventors: Marc R. Matsen, Lee C. Firth, David S. Nansen, Michael R. Zolnowski, Carey E. Wilkinson, Gregory A. Foltz
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Patent number: 10703027Abstract: Provided are induction heating cells including pressure bladders used for supporting dies and methods of using these induction heating cells. A pressure bladder may be disposed between a die and a bolster of the cell. Even when the bolster is deformed during operation of the cell, the pressure bladder continues to provide uniform support to the die thereby preserving integrity of the die and prevents its cracking or braking. As such, the cell may be operated at a higher processing pressure inside the cavity formed by the die without further strengthening the bolster. The bolster is allowed to deform without compromising the integrity of the die. The deformation of the bolster is compensated by the shape change of the pressure bladder. The number and/or position of the bladders in the cell may depend on the shape of processed parts.Type: GrantFiled: September 6, 2019Date of Patent: July 7, 2020Assignee: The Boeing CompanyInventors: Marc R. Matsen, David S. Nansen, Lee C. Firth, Carey E. Wilkinson, Gregory J. Hickman, William C. Dykstra
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Patent number: 10569504Abstract: A panel comprises a first face sheet and a second face sheet spaced apart from the first face sheet. The panel further comprises a core sheet intercoupled between the first face sheet and the second face sheet. Each of the first and second face sheets is made of a material having a thermal expansion that is different from the thermal expansion of the other face sheet.Type: GrantFiled: February 27, 2017Date of Patent: February 25, 2020Assignee: The Boeing CompanyInventors: Marc R. Matsen, Lee C. Firth, David S. Nansen, Michael R. Zolnowski, Carey E. Wilkinson, Gregory A. Foltz
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Publication number: 20190389099Abstract: Provided are induction heating cells including pressure bladders used for supporting dies and methods of using these induction heating cells. A pressure bladder may be disposed between a die and a bolster of the cell. Even when the bolster is deformed during operation of the cell, the pressure bladder continues to provide uniform support to the die thereby preserving integrity of the die and prevents its cracking or braking. As such, the cell may be operated at a higher processing pressure inside the cavity formed by the die without further strengthening the bolster. The bolster is allowed to deform without compromising the integrity of the die. The deformation of the bolster is compensated by the shape change of the pressure bladder. The number and/or position of the bladders in the cell may depend on the shape of processed parts.Type: ApplicationFiled: September 6, 2019Publication date: December 26, 2019Applicant: The Boeing CompanyInventors: Marc R. Matsen, David S. Nansen, Lee C. Firth, Carey E. Wilkinson, Gregory J. Hickman, William C. Dykstra
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Patent number: 10464240Abstract: Provided are induction heating cells including pressure bladders used for supporting dies and methods of using these induction heating cells. A pressure bladder may be disposed between a die and a bolster of the cell. Even when the bolster is deformed during operation of the cell, the pressure bladder continues to provide uniform support to the die thereby preserving integrity of the die and prevents its cracking or braking. As such, the cell may be operated at a higher processing pressure inside the cavity formed by the die without further strengthening the bolster. The bolster is allowed to deform without compromising the integrity of the die. The deformation of the bolster is compensated by the shape change of the pressure bladder. The number and/or position of the bladders in the cell may depend on the shape of processed parts.Type: GrantFiled: November 19, 2015Date of Patent: November 5, 2019Assignee: The Boeing CompanyInventors: Marc R. Matsen, David S. Nansen, Lee C. Firth, Carey E. Wilkinson, Gregory J. Hickman, William C. Dykstra
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Patent number: 10265770Abstract: A metal injection molding apparatus includes a metal injection mold die having first and second die halves, a first set of features provided in the first die half, a second set of features provided in the second die half and complementary to the first set of features provided in the first are half and an ultrasonic transducer disposed in contact with the metal injection mold die. A binderless metal injection molding method is also disclosed.Type: GrantFiled: September 17, 2014Date of Patent: April 23, 2019Assignee: The Boeing CompanyInventor: Carey E Wilkinson
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Publication number: 20180244016Abstract: A panel comprises a first face sheet and a second face sheet spaced apart from the first face sheet. The panel further comprises a core sheet intercoupled between the first face sheet and the second face sheet. Each of the first and second face sheets is made of a material having a thermal expansion that is different from the thermal expansion of the other face sheet.Type: ApplicationFiled: February 27, 2017Publication date: August 30, 2018Applicant: The Boeing CompanyInventors: Marc R. Matsen, Lee C. Firth, David S. Nansen, Michael R. Zolnowski, Carey E. Wilkinson, Gregory A. Foltz
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Publication number: 20170368604Abstract: Methods for forming near net-shape metal parts include transporting a binderless metal powder mixture to a die cavity with ultrasonic energy, introducing the binderless metal powder mixture into the die cavity, and compacting the binderless metal powder mixture within the die cavity with ultrasonic energy to form a green part within the die cavity. The binderless metal powder mixture includes essentially no plastic or binder, and may consist essentially of metal particles. The methods may further include separating the green part from the mold die and sintering the green part, after separating, to form a sintered near net-shape metal part.Type: ApplicationFiled: September 6, 2017Publication date: December 28, 2017Inventor: Carey E. Wilkinson
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Patent number: 9782828Abstract: Systems and methods for forming near net-shape metal parts from binderless metal powder are disclosed. Systems include a mold die that defines a die cavity and may include one or more ultrasonic transducers operatively coupled to the mold die. Systems may be configured to introduce binderless metal powder into a die cavity and/or to compact the binderless metal powder within the die cavity. Methods include introducing binderless metal powder into a die cavity of a mold die and compacting the binderless metal powder within the die cavity to form a green part within the die cavity. The binderless metal powder may include spheroidal metal particles and angular metal particles. The methods may further include separating the green part from the mold die and sintering the green part, after separating, to form a sintered near net-shape metal part.Type: GrantFiled: October 20, 2014Date of Patent: October 10, 2017Assignee: The Boeing CompanyInventor: Carey E. Wilkinson
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Patent number: 9662742Abstract: A method and apparatus is presented. A method may comprise positioning a metallic bladder within a tool, the tool having a number of die liners that generate heat when exposed to a magnetic field; applying the magnetic field to the number of die liners to heat the metallic bladder; and pressurizing the metallic bladder.Type: GrantFiled: July 7, 2014Date of Patent: May 30, 2017Assignee: THE BOEING COMPANYInventors: Marc Rollo Matsen, Alexander M. Rubin, Randall Dow Wilkerson, Carey E. Wilkinson, James Rodney Fox, Charles R. Prebil, Gregory James Schoepen Hickman, Jeffery Lee Marcoe
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Publication number: 20170144337Abstract: Provided are induction heating cells including pressure bladders used for supporting dies and methods of using these induction heating cells. A pressure bladder may be disposed between a die and a bolster of the cell. Even when the bolster is deformed during operation of the cell, the pressure bladder continues to provide uniform support to the die thereby preserving integrity of the die and prevents its cracking or braking. As such, the cell may be operated at a higher processing pressure inside the cavity formed by the die without further strengthening the bolster. The bolster is allowed to deform without compromising the integrity of the die. The deformation of the bolster is compensated by the shape change of the pressure bladder. The number and/or position of the bladders in the cell may depend on the shape of processed parts.Type: ApplicationFiled: November 19, 2015Publication date: May 25, 2017Applicant: The Boeing CompanyInventors: Marc R. Matsen, David S. Nansen, Lee C. Firth, Carey E. Wilkinson, Gregory J. Hickman, William C. Dykstra
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Patent number: 9635714Abstract: An induction heating system for manufacturing a part including an induction coil and a smart susceptor positioned within an oscillating electromagnetic field from the induction coil. The smart susceptor includes a ferromagnetic material cold sprayed onto a tool. The tool may be a sheet metal component formed to a desired shape by incremental sheet forming. The smart susceptor may be heated up by eddy currents generated in the ferromagnetic material by the oscillating electromagnetic field. The smart susceptor may be designed to have a desired Curie temperature based on the composition of the ferromagnetic material. The smart susceptor is formed into a desired shape by cold spraying ferromagnetic material onto a tool already formed into the desired shape. The smart susceptor may be removed from the tool by thermally shocking the smart susceptor and the tool and may be used to heat a part to be formed.Type: GrantFiled: May 6, 2013Date of Patent: April 25, 2017Assignee: THE BOEING COMPANYInventors: Marc R. Matsen, Carey E. Wilkinson
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Publication number: 20160107235Abstract: Systems and methods for forming near net-shape metal parts from binderless metal powder are disclosed. Systems include a mold die that defines a die cavity and may include one or more ultrasonic transducers operatively coupled to the mold die. Systems may be configured to introduce binderless metal powder into a die cavity and/or to compact the binderless metal powder within the die cavity. Methods include introducing binderless metal powder into a die cavity of a mold die and compacting the binderless metal powder within the die cavity to form a green part within the die cavity. The binderless metal powder may include spheroidal metal particles and angular metal particles. The methods may further include separating the green part from the mold die and sintering the green part, after separating, to form a sintered near net-shape metal part.Type: ApplicationFiled: October 20, 2014Publication date: April 21, 2016Applicant: The Boeing CompanyInventor: Carey E. Wilkinson
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Publication number: 20150013894Abstract: A method and apparatus is presented. A method may comprise positioning a metallic bladder within a tool, the tool having a number of die liners that generate heat when exposed to a magnetic field; applying the magnetic field to the number of die liners to heat the metallic bladder; and pressurizing the metallic bladder.Type: ApplicationFiled: July 7, 2014Publication date: January 15, 2015Inventors: Marc Rollo Matsen, Alexander M. Rubin, Randall Dow Wilkerson, Carey E. Wilkinson, James Rodney Fox, Charles R. Prebil, Gregory James Schoepen Hickman, Jeffery Lee Marcoe
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Publication number: 20150004047Abstract: A metal injection molding apparatus includes a metal injection mold die having first and second die halves, a first set of features provided in the first die half, a second set of features provided in the second die half and complementary to the first set of features provided in the first are half and an ultrasonic transducer disposed in contact with the metal injection mold die. A binderless metal injection molding method is also disclosed.Type: ApplicationFiled: September 17, 2014Publication date: January 1, 2015Inventor: Carey E. Wilkinson
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Publication number: 20120237385Abstract: A metal injection molding apparatus includes a metal injection mold die having first and second die halves, a first set of features provided in the first die half, a second set of features provided in the second die half and complementary to the first set of features provided in the first die half and an ultrasonic transducer disposed in contact with the metal injection mold die. A binderless metal injection molding method is also disclosed.Type: ApplicationFiled: June 1, 2012Publication date: September 20, 2012Inventor: Carey E. Wilkinson
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Patent number: 7644629Abstract: A tensile specimen measuring apparatus includes a generally elongated base, a generally elongated pin channel provided in the base, a measuring pin carrier slidably mounted in the pin channel of the base, at least one contact pin carried by the measuring pin carrier, at least one contact pin disposed at an end of the pin channel of the base in generally spaced-apart relationship with respect to the at least one contact pin carried by the measuring pin carrier and an electronic measuring device engaging the at least one contact pin carried by the measuring pin carrier. A tensile specimen measuring method is also disclosed.Type: GrantFiled: February 12, 2008Date of Patent: January 12, 2010Assignee: The Boeing CompanyInventors: Carey E. Wilkinson, William Lamey, III
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Publication number: 20090208360Abstract: A metal injection molding apparatus includes a metal injection mold die having first and second die halves, a first set of features provided in the first die half, a second set of features provided in the second die half and complementary to the first set of features provided in the first die half and an ultrasonic transducer disposed in contact with the metal injection mold die. A binderless metal injection molding method is also disclosed.Type: ApplicationFiled: February 20, 2008Publication date: August 20, 2009Inventor: Carey E. Wilkinson
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Publication number: 20090199652Abstract: A tensile specimen measuring apparatus includes a generally elongated base, a generally elongated pin channel provided in the base, a measuring pin carrier slidably mounted in the pin channel of the base, at least one contact pin carried by the measuring pin carrier, at least one contact pin disposed at an end of the pin channel of the base in generally spaced-apart relationship with respect to the at least one contact pin carried by the measuring pin carrier and an electronic measuring device engaging the at least one contact pin carried by the measuring pin carrier. A tensile specimen measuring method is also disclosed.Type: ApplicationFiled: February 12, 2008Publication date: August 13, 2009Inventors: Carey E. Wilkinson, William Lamey, III