Patents by Inventor Derek Anthony Rice
Derek Anthony Rice 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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Patent number: 11125158Abstract: A system for delivering a flow stream of a gas to a compressor. A shroud extends from an inlet to the compressor and defines a main inlet passage configured to direct the flow stream from the inlet to the compressor. A communication plenum is separated from the main inlet passage. A port system includes first and second port subsystems that each provide an opening between the main inlet passage and the communication plenum. The first port subsystem is disposed further from the compressor than the second port subsystem. The port system is configured so that a portion of the gas enters or exits the compressor through the second port subsystem, depending on operating conditions of the compressor.Type: GrantFiled: September 17, 2018Date of Patent: September 21, 2021Assignee: HONEYWELL INTERNATIONAL INC.Inventors: Bruce Dan Bouldin, Derek Anthony Rice, Michael Todd Barton, Raymond Mccage, Yates Wong, Kevin Sing
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Patent number: 11072435Abstract: A turboprop engine system for an aircraft includes an engine, a propeller, and a gear train coupled to and configured to provide power from the engine to the propeller at a predetermined gear reduction. The engine system also includes a gearbox that houses at least part of the gear train. The gearbox includes a gearbox flow structure and an inlet flow structure that is removably attached to the gearbox. The inlet flow structure and the gearbox flow structure cooperate to define an inlet flow passage to the engine. The inlet flow passage has an upstream end and a downstream end that are cooperatively defined by the inlet flow structure and the gearbox flow structure. The upstream end is configured to receive an airstream that is directed along the inlet flow passage to the downstream end and toward the engine.Type: GrantFiled: October 25, 2018Date of Patent: July 27, 2021Assignee: HONEYWELL INTERNATIONAL INC.Inventors: Raymond Mccage, Derek Anthony Rice, Joseph Becar, Yates Wong, Brian Jardine, Bruce Dan Bouldin, Kevin Sing
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Publication number: 20200130857Abstract: A turboprop engine system for an aircraft includes an engine, a propeller, and a gear train coupled to and configured to provide power from the engine to the propeller at a predetermined gear reduction. The engine system also includes a gearbox that houses at least part of the gear train. The gearbox includes a gearbox flow structure and an inlet flow structure that is removably attached to the gearbox. The inlet flow structure and the gearbox flow structure cooperate to define an inlet flow passage to the engine. The inlet flow passage has an upstream end and a downstream end that are cooperatively defined by the inlet flow structure and the gearbox flow structure. The upstream end is configured to receive an airstream that is directed along the inlet flow passage to the downstream end and toward the engine.Type: ApplicationFiled: October 25, 2018Publication date: April 30, 2020Applicant: HONEYWELL INTERNATIONAL INC.Inventors: Raymond Mccage, Derek Anthony Rice, Joseph Becar, Yates Wong, Brian Jardine, Bruce Dan Bouldin, Kevin Sing
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Publication number: 20200088097Abstract: A system for delivering a flow stream of a gas to a compressor. A shroud extends from an inlet to the compressor and defines a main inlet passage configured to direct the flow stream from the inlet to the compressor. A communication plenum is separated from the main inlet passage. A port system includes first and second port subsystems that each provide an opening between the main inlet passage and the communication plenum. The first port subsystem is disposed further from the compressor than the second port subsystem. The port system is configured so that a portion of the gas enters or exits the compressor through the second port subsystem, depending on operating conditions of the compressor.Type: ApplicationFiled: September 17, 2018Publication date: March 19, 2020Applicant: HONEYWELL INTERNATIONAL INC.Inventors: Bruce Dan Bouldin, Derek Anthony Rice, Michael Todd Barton, Raymond Mccage, Yates Wong, Kevin Sing
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Patent number: 9759261Abstract: High temperature rolling element bearings and methods for manufacturing high temperature bearing components, such as bearing races or rings, are provided. In one embodiment, the method includes obtaining a powder mixture containing a superalloy powder admixed with hard wear particles, such as carbide particles. The powder mixture is consolidated utilizing a spark plasma sintering process during which the powder mixture is compressed into a sintered blank, while an electrical current is conducted through the powder mixture to heat the powder mixture to a sintering temperature. The sintered blank is then machined to impart the bearing component with its final shape. Precipitate hardening may also be performed, if desired. The spark plasma sintering process is controlled to limit the temperature and duration of the powder consolidation process thereby imparting the resulting bearing component with an enhanced hot hardness and other desirable properties at highly elevated operating temperatures.Type: GrantFiled: November 18, 2015Date of Patent: September 12, 2017Assignee: HONEYWELL INTERNATIONAL INC.Inventors: Amer Aizaz, Derek Anthony Rice
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Publication number: 20170138402Abstract: High temperature rolling element bearings and methods for manufacturing high temperature bearing components, such as bearing races or rings, are provided. In one embodiment, the method includes obtaining a powder mixture containing a superalloy powder admixed with hard wear particles, such as carbide particles. The powder mixture is consolidated utilizing a spark plasma sintering process during which the powder mixture is compressed into a sintered blank, while an electrical current is conducted through the powder mixture to heat the powder mixture to a sintering temperature. The sintered blank is then machined to impart the bearing component with its final shape. Precipitate hardening may also be performed, if desired. The spark plasma sintering process is controlled to limit the temperature and duration of the powder consolidation process thereby imparting the resulting bearing component with an enhanced hot hardness and other desirable properties at highly elevated operating temperatures.Type: ApplicationFiled: November 18, 2015Publication date: May 18, 2017Applicant: HONEYWELL INTERNATIONAL INC.Inventors: Amer Aizaz, Derek Anthony Rice
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Publication number: 20170114471Abstract: A method for manufacturing a valve assembly includes the steps of: providing one or more nickel-based superalloy components of the valve assembly, wherein the one or more components are designed to be subjected to operating environments including temperatures of about 760° C., +/?about 30° C.; aluminizing the one or more components using an aluminizing process, wherein the aluminizing process causes inter-diffusion between the nickel-based superalloy and aluminum as well as forms an aluminum-rich surface layer on the one or more components, thereby forming one or more aluminized components; and subjecting the one or more aluminized components to a plasma electrolytic oxidation process to convert the aluminum rich surface layer into a hard, wear-resistant, and oxidation-resistant aluminum oxide coating layer, wherein the hardness, wear-resistance, and oxidation-resistance of the aluminum oxide coating layer is maintained in the operating environments including temperatures of about 760° C., +/?about 30° C.Type: ApplicationFiled: October 27, 2015Publication date: April 27, 2017Applicant: HONEYWELL INTERNATIONAL INC.Inventors: Derek Anthony Rice, Amer Aizaz, James Piascik
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Patent number: 9216453Abstract: Methods of forming dual microstructure components include consolidating a powder material comprising an alloy to form a billet, the billet having a first grain structure, inductively heating the billet at an inductive heat treat temperature above a gamma prime solvus temperature of the alloy and subjecting the billet to a subsolvus heat treat temperature that is below the gamma prime solvus temperature of the alloy, waiting a period of time for the first grain structure in an outer portion of the billet to transform into a second grain structure that is coarser than the first grain structure, after the steps of inductively heating and subjecting the billet to the subsolvus heat treat temperature. The methods also include dividing the billet into at least two sections, and machining a final shape into one or more of the at least two sections to form the dual microstructure component.Type: GrantFiled: November 20, 2009Date of Patent: December 22, 2015Assignee: HONEYWELL INTERNATIONAL INC.Inventors: Brian Hann, Derek Anthony Rice, Daniel Greving
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Patent number: 8187724Abstract: There is provided a method for fabricating a dual alloy structure that may in turn be machined to fabricate a rotary component for use in a gas turbine engine. The method provides a powder metal (PM) nickel based superalloy and a nickel aluminide intermetallic based alloy. The powder metal (PM) nickel based superalloy displays characteristics, such as improved strength, low cycle fatigue resistance, fracture toughness, and crack growth resistance. The nickel aluminide intermetallic based alloy displays characteristics, such as high temperature creep and oxidation resistance, suitable for use in the outer radial area of an impeller. A bore sub-element is fabricated from the powder metal (PM) nickel based superalloy. A body sub-element is fabricated from the nickel aluminide intermetallic based alloy. The bore sub-element and body sub-element are joined by inertia welding or diffusion bonding at a common mating surface.Type: GrantFiled: February 24, 2009Date of Patent: May 29, 2012Assignee: Honeywell International Inc.Inventor: Derek Anthony Rice
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Publication number: 20110123385Abstract: Methods of forming dual microstructure components include consolidating a powder material comprising an alloy to form a billet, the billet having a first grain structure, inductively heating the billet at an inductive heat treat temperature above a gamma prime solvus temperature of the alloy and subjecting the billet to a subsolvus heat treat temperature that is below the gamma prime solvus temperature of the alloy, waiting a period of time for the first grain structure in an outer portion of the billet to transform into a second grain structure that is coarser than the first grain structure, after the steps of inductively heating and subjecting the billet to the subsolvus heat treat temperature. The methods also include dividing the billet into at least two sections, and machining a final shape into one or more of the at least two sections to form the dual microstructure component.Type: ApplicationFiled: November 20, 2009Publication date: May 26, 2011Applicant: HONEYWELL INTERNATIONAL INC.Inventors: Brian Hann, Derek Anthony Rice, Daniel Greving
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Publication number: 20100233504Abstract: There is provided a method for fabricating a dual microstructure component that may in turn be machined to fabricate a rotary element such as an impeller characterized as capable of withstanding high heat conditions for use in a gas turbine engine. The method provides a nickel based superalloy suitable for application of an impeller in a gas turbine engine. The bore region is manufactured having a grain size finer than ASTM 10.0 and the body region is manufactured having a grain size coarser than ASTM 7.0. The bore region and the body region define a dual microstructure and an interface.Type: ApplicationFiled: March 13, 2009Publication date: September 16, 2010Applicant: Honeywell International Inc.Inventors: Derek Anthony RICE, Brian HANN, Pete KANTZOS
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Publication number: 20100215978Abstract: There is provided a method for fabricating a dual alloy structure that may in turn be machined to fabricate a rotary component for use in a gas turbine engine. The method provides a powder metal (PM) nickel based superalloy and a nickel aluminide intermetallic based alloy. The powder metal (PM) nickel based superalloy displays characteristics, such as improved strength, low cycle fatigue resistance, fracture toughness, and crack growth resistance. The nickel aluminide intermetallic based alloy displays characteristics, such as high temperature creep and oxidation resistance, suitable for use in the outer radial area of an impeller. A bore sub-element is fabricated from the powder metal (PM) nickel based superalloy. A body sub-element is fabricated from the nickel aluminide intermetallic based alloy. The bore sub-element and body sub-element are joined by inertia welding or diffusion bonding at a common mating surface.Type: ApplicationFiled: February 24, 2009Publication date: August 26, 2010Applicant: HONEYWELL INTERNATIONAL INC.Inventor: Derek Anthony Rice