Patents by Inventor Eric W. Karlen
Eric W. Karlen 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: 11933554Abstract: A heat exchanger includes a body defining a flow channel, and a pin extending across the flow channel, the pin including an at least partially non-cylindrical shape. The pin can be a double helix pin including two spiral branches defining a double helix shape. The two branches can include a uniform winding radius. The two branches include a non-uniform winding radius. The non-uniform winding radius can include a base radius and a midpoint radius, wherein the midpoint radius is smaller than the base radius. The two branches can be joined together by one or more cross-members.Type: GrantFiled: October 4, 2021Date of Patent: March 19, 2024Assignee: Hamilton Sundstrand CorporationInventors: Eric W. Karlen, William L. Wentland
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Patent number: 11912396Abstract: An assembly and a method for manufacturing an assembly for transmitting torque to an aircraft actuator. The assembly and method include a torque tube having a longitudinal axis and an end fitting. The ending fitting includes a connector portion and an engagement portion that is inserted into the torque tube. The engagement portion includes a first end adjacent the connector portion, a second end opposite the first end, and a coupling region between the first and second end that includes an outer coupling surface having an outer diameter and a continuous groove formed thereon. The continuous groove includes two axial grooves that extend along the outer coupling surface along the longitudinal axis and a first parallel groove that extends circumferentially about the longitudinal axis along the outer coupling surface that joins the two axial grooves.Type: GrantFiled: October 21, 2020Date of Patent: February 27, 2024Assignee: HAMILTON SUNDSTRAND CORPORATIONInventors: Victor Barger, Joseph M. Bielefeldt, Jude C. Lai, Eric W. Karlen
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Publication number: 20230373022Abstract: A method of improving an internal surface topography of a manufactured workpiece includes filling a workpiece with an electrically conductive magnetorheological (MR) fluid. The workpiece includes at least one internal feature having an inner surface with at least one irregularity. The method further includes converting the MR fluid into a rigid MR material, applying a voltage to the rigid MR material, and ablating the inner surface in response to the voltage to remove the at least one irregularity.Type: ApplicationFiled: May 17, 2022Publication date: November 23, 2023Inventors: Jordan Pugliese, Sergey Mironets, Eric W. Karlen
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Patent number: 11801554Abstract: An additive manufacturing method includes cold spraying a powder onto a build area to create a densified powder layer. The method can include high speed machining the densified powder layer after cold spraying to create a smooth layer.Type: GrantFiled: February 7, 2020Date of Patent: October 31, 2023Assignee: Hamilton Sundstrand CorporationInventor: Eric W. Karlen
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Patent number: 11745278Abstract: An additive manufactured workpiece includes one or more cavities having an inner surface. A dielectric interface is formed in the cavity, and conforms to the inner surface. The additive manufactured workpiece further includes an in-situ electrode in the cavities. The dielectric interface is interposed between the in-situ electrode and the inner surface of the workpiece.Type: GrantFiled: October 20, 2020Date of Patent: September 5, 2023Assignee: HAMILTON SUNDSTRAND CORPORATIONInventors: Mark R. Jaworowski, Eric W. Karlen, Gary M. Lomasney, Sergey Mironets
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Publication number: 20230264265Abstract: An additively manufactured intermediate part includes a body and at least one sacrificial electrode formed within or upon the body. The body includes a plurality of layers and at least one surface having a region to be smoothed in a near-finished state of the additively manufactured intermediate part. The at least one sacrificial electrode is adjacent to the body along the at least one surface, such that at least one of the plurality of layers is adjacent to the at least one sacrificial electrode in the region to be smoothed in the near-finished state of the additively manufactured intermediate part.Type: ApplicationFiled: February 18, 2022Publication date: August 24, 2023Inventors: Cody Coogan, Eric W. Karlen
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Patent number: 11458570Abstract: An additive manufacturing process is disclosed that involves positioning a metallic layer beneath a component substrate and welding the metallic layer to the component substrate using laser energy.Type: GrantFiled: April 1, 2019Date of Patent: October 4, 2022Assignee: Hamilton Sundstrand CorporationInventors: Eric W. Karlen, Sergey Mironets
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Publication number: 20220028751Abstract: A heat exchanger includes a body defining a flow channel, and a pin extending across the flow channel, the pin including an at least partially non-cylindrical shape. The pin can be a double helix pin including two spiral branches defining a double helix shape. The two branches can include a uniform winding radius. The two branches include a non-uniform winding radius. The non-uniform winding radius can include a base radius and a midpoint radius, wherein the midpoint radius is smaller than the base radius. The two branches can be joined together by one or more cross-members.Type: ApplicationFiled: October 4, 2021Publication date: January 27, 2022Applicant: Hamilton Sundstrand CorporationInventors: Eric W. Karlen, William L. Wentland
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Patent number: 11139221Abstract: A heat exchanger includes a body defining a flow channel, and a pin extending across the flow channel, the pin including an at least partially non-cylindrical shape. The pin can be a double helix pin including two spiral branches defining a double helix shape. The two branches can include a uniform winding radius. The two branches include a non-uniform winding radius. The non-uniform winding radius can include a base radius and a midpoint radius, wherein the midpoint radius is smaller than the base radius. The two branches can be joined together by one or more cross-members.Type: GrantFiled: July 27, 2018Date of Patent: October 5, 2021Assignee: Hamilton Sundstrand CorporationInventors: Eric W. Karlen, William L. Wentland
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Patent number: 11123819Abstract: A method of making an article is disclosed. According to the method, an energy beam is directed to a build location on a substrate, and a first powder material is delivered to the build location on the substrate and melted with the energy beam. A second powder material is delivered to the build location on the substrate over the first material and melted with the energy beam. The direction of the energy beam and delivery and melting of the first and second powders is repeated at multiple build locations on the substrate to form a solid surface of the article of the second material. The solid surface comprising the second material is subjected to a finishing process.Type: GrantFiled: September 25, 2017Date of Patent: September 21, 2021Assignee: HAMILTON SUNDSTRAND CORPORATIONInventors: Eric W. Karlen, William Louis Wentland
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Patent number: 11101608Abstract: A conductor assembly can include one or more conductors formed by a conductive material, and one or more filter cores formed integrally on and at least partially around the one or more conductors. The one or more filter cores can be formed of a material different than the conductive material and can be configured to reduce electromagnetic emissions from the one or more conductors.Type: GrantFiled: October 31, 2018Date of Patent: August 24, 2021Assignee: Hamilton Sundstrand CorporationInventors: Timothy Arn Goodrich, Eric W. Karlen, Mark W. Metzler
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Publication number: 20210147067Abstract: An assembly and a method for manufacturing an assembly for transmitting torque to an aircraft actuator. The assembly and method include a torque tube having a longitudinal axis and an end fitting. The ending fitting includes a connector portion and an engagement portion that is inserted into the torque tube. The engagement portion includes a first end adjacent the connector portion, a second end opposite the first end, and a coupling region between the first and second end that includes an outer coupling surface having an outer diameter and a continuous groove formed thereon. The continuous groove includes two axial grooves that extend along the outer coupling surface along the longitudinal axis and a first parallel groove that extends circumferentially about the longitudinal axis along the outer coupling surface that joins the two axial grooves.Type: ApplicationFiled: October 21, 2020Publication date: May 20, 2021Inventors: Victor Barger, Joseph M. Bielefeldt, Jude C. Lai, Eric W. Karlen
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Patent number: 10974321Abstract: An additive manufacturing system for building a product includes a base plate for mounting the product thereon, and at least one heating element shaped to at least partially conform to the product and configured to apply heat to at least a portion of the product as the product is additively manufactured to reduce thermal gradients in the product.Type: GrantFiled: October 11, 2019Date of Patent: April 13, 2021Assignee: Hamilton Sundstrand CorporationInventor: Eric W. Karlen
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Publication number: 20210031286Abstract: An additive manufactured workpiece includes one or more cavities having an inner surface. A dielectric interface is formed in the cavity, and conforms to the inner surface. The additive manufactured workpiece further includes an in-situ electrode in the cavities. The dielectric interface is interposed between the in-situ electrode and the inner surface of the workpiece.Type: ApplicationFiled: October 20, 2020Publication date: February 4, 2021Inventors: Mark R. Jaworowski, Eric W. Karlen, Gary M. Lomasney, Sergey Mironets
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Patent number: 10870159Abstract: An additive manufactured workpiece includes one or more cavities having an inner surface. A dielectric interface is formed in the cavity, and conforms to the inner surface. The additive manufactured workpiece further includes an in-situ electrode in the cavities. The dielectric interface is interposed between the in-situ electrode and the inner surface of the workpiece.Type: GrantFiled: November 2, 2017Date of Patent: December 22, 2020Assignee: HAMILTON SUNSTRAND CORPORATIONInventors: Mark R. Jaworowski, Eric W. Karlen, Gary M. Lomasney, Sergey Mironets
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Patent number: 10862378Abstract: A method of manufacturing a rotor of an electric motor or an electric generator includes positioning a plurality of amortisseur bars and using additive manufacturing to place electrically conductive material. More specifically, positioning the amortisseur bars may include circumferentially positioning the bars around a rotor stack and using additive manufacturing to place electrically conductive material may include forming a non-solid pattern of electrically conductive material, such as a pattern of electrically conductive traces, across opposite axial ends of the rotor stack to electrically interconnect an amortisseur circuit.Type: GrantFiled: February 6, 2020Date of Patent: December 8, 2020Assignee: HAMILTON SUNDSTRAND CORPORATIONInventors: William Louis Wentland, Eric W. Karlen, Dhaval Patel, Andrew R. Wilkinson
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Publication number: 20200306881Abstract: An additive manufacturing process is disclosed that involves positioning a metallic layer beneath a component substrate and welding the metallic layer to the component substrate using laser energy.Type: ApplicationFiled: April 1, 2019Publication date: October 1, 2020Inventors: Eric W. Karlen, Sergey Mironets
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Patent number: 10788435Abstract: An inspection fixture includes a base member, a support member coupled to base member, and an intermediate member coupled to the support member or the base member. The support member includes a radiolucent material for limiting artifacts in imagery of an industrial article supported by the inspection fixture. Inspection arrangements and imaging methods are also described.Type: GrantFiled: December 21, 2017Date of Patent: September 29, 2020Assignee: Hamilton Sundstrand CorporationInventors: Eric W. Karlen, Daniel O. Ursenbach, Claire Victoria Brennan, Michael Hamilton Severson
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Publication number: 20200180027Abstract: An additive manufacturing method includes cold spraying a powder onto a build area to create a densified powder layer. The method can include high speed machining the densified powder layer after cold spraying to create a smooth layer.Type: ApplicationFiled: February 7, 2020Publication date: June 11, 2020Applicant: Hamilton Sundstrand CorporationInventor: Eric W. Karlen
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Publication number: 20200177061Abstract: A method of manufacturing a rotor of an electric motor or an electric generator includes positioning a plurality of amortisseur bars and using additive manufacturing to place electrically conductive material. More specifically, positioning the amortisseur bars may include circumferentially positioning the bars around a rotor stack and using additive manufacturing to place electrically conductive material may include forming a non-solid pattern of electrically conductive material, such as a pattern of electrically conductive traces, across opposite axial ends of the rotor stack to electrically interconnect an amortisseur circuit.Type: ApplicationFiled: February 6, 2020Publication date: June 4, 2020Applicant: HAMILTON SUNDSTRAND CORPORATIONInventors: William Louis Wentland, Eric W. Karlen, Dhaval Patel, Andrew R. Wilkinson