Patents by Inventor Jeffery L. Marcoe
Jeffery L. Marcoe 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: 11110647Abstract: Systems and processes that integrate thermoplastic and shape memory alloy materials to form an adaptive composite structure capable of changing its shape. For example, the adaptive composite structure may be designed to serve as a multifunctional adaptive wing flight control surface. Other applications for such adaptive composite structures include in variable area fan nozzles, winglets, fairings, elevators, rudders, or other aircraft components having an aerodynamic surface whose shape is preferably controllable. The material systems can be integrated by means of overbraiding (interwoven) with tows of both thermoplastic and shape memory alloy materials or separate layers of each material can be consolidated (e.g., using induction heating) to make a flight control surface that does not require separate actuation.Type: GrantFiled: April 26, 2018Date of Patent: September 7, 2021Assignee: The Boeing CompanyInventors: Jeffery L. Marcoe, Sahrudine Apdalhaliem, Moushumi Shome
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Patent number: 10828847Abstract: A fiber placement system including a fiber placement station at a first location, the fiber placement station including a tool and a fiber placement assembly configured to construct a reinforcement layup on the tool, the first fiber placement assembly including a compaction roller rotatable about an axis of rotation, the compaction roller at least partially defining a nip, a thermoplastic composite ply extending through the nip and a heating unit positioned to heat the thermoplastic composite ply proximate the nip, and a consolidation station at a consolidation location, the consolidation location being different from the first location, the consolidation station including a consolidation tool and a consolidation system configured to consolidate a reinforcement layup assembly that includes the reinforcement layup.Type: GrantFiled: June 14, 2018Date of Patent: November 10, 2020Assignee: The Boeing CompanyInventors: Marc R. Matsen, Mark A. Negley, Jeffery L. Marcoe, Stephen G. Moore, Brice A. Johnson, Alexandra K. Dillon, Megan M. Petersen
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Patent number: 10774858Abstract: Provided are assemblies having composite structures interlocked with shape memory alloy structures and methods of fabricating such assemblies. Interlocking may involve inserting an interlocking protrusion of a shape memory alloy structure into an interlocking opening of a composite structure and heating at least this protrusion of the shape memory alloy structure to activate the alloy and change the shape of the protrusion. This shape change engages the protrusion in the opening such that the protrusion cannot be removed from the opening. The shape memory alloy structure may be specifically trained prior to forming an assembly using a combination of thermal cycling and deformation to achieve specific pre-activation and post-activation shapes. The pre-activation shape allows inserting the interlocking protrusion into the opening, while the post-activation shape engages the interlocking protrusion within the opening. As such, activation of the shape memory alloy interlocks the two structures.Type: GrantFiled: June 22, 2017Date of Patent: September 15, 2020Assignee: The Boeing CompanyInventors: Waeil M. Ashmawi, Jaime C. Garcia, Sahrudine Apdalhaliem, Jeffery L. Marcoe, Moushumi Shome
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Patent number: 10744722Abstract: A radius filler includes a plurality of fibers encapsulated in resin and braided into a braided radius filler. The braided radius filler has a substantially triangular shape with concave radius filler side surfaces and a substantially planar radius filler base surface.Type: GrantFiled: October 30, 2017Date of Patent: August 18, 2020Assignee: The Boeing CompanyInventors: Angelo Rossi, Jeffery L. Marcoe, Marc R. Matsen, Aaron W. Bartel, Waeil M. Ashmawi, Sahrudine Apdalhaliem, Adriana Willempje Blom-Schieber, David Reusch
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Publication number: 20180290402Abstract: A fiber placement system including a fiber placement station at a first location, the fiber placement station including a tool and a fiber placement assembly configured to construct a reinforcement layup on the tool, the first fiber placement assembly including a compaction roller rotatable about an axis of rotation, the compaction roller at least partially defining a nip, a thermoplastic composite ply extending through the nip and a heating unit positioned to heat the thermoplastic composite ply proximate the nip, and a consolidation station at a consolidation location, the consolidation location being different from the first location, the consolidation station including a consolidation tool and a consolidation system configured to consolidate a reinforcement layup assembly that includes the reinforcement layup.Type: ApplicationFiled: June 14, 2018Publication date: October 11, 2018Applicant: The Boeing CompanyInventors: Marc R. Matsen, Mark A. Negley, Jeffery L. Marcoe, Stephen G. Moore, Brice A. Johnson, Alexandra K. Dillon, Megan M. Petersen
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Publication number: 20180243972Abstract: Systems and processes that integrate thermoplastic and shape memory alloy materials to form an adaptive composite structure capable of changing its shape. For example, the adaptive composite structure may be designed to serve as a multifunctional adaptive wing flight control surface. Other applications for such adaptive composite structures include in variable area fan nozzles, winglets, fairings, elevators, rudders, or other aircraft components having an aerodynamic surface whose shape is preferably controllable. The material systems can be integrated by means of overbraiding (interwoven) with tows of both thermoplastic and shape memory alloy materials or separate layers of each material can be consolidated (e.g., using induction heating) to make a flight control surface that does not require separate actuation.Type: ApplicationFiled: April 26, 2018Publication date: August 30, 2018Applicant: The Boeing CompanyInventors: Jeffery L. Marcoe, Sahrudine Apdalhaliem, Moushumi Shome
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Patent number: 10058950Abstract: An induction welding system is provided. The system includes at least one induction coil configured to generate an alternating magnetic field, and a smart susceptor film sized to be positioned between a first component and a second component to be welded to the first component. The smart susceptor film includes a thermoplastic resin, and a plurality of metal alloy wires disposed in the thermoplastic resin such that the plurality of metal alloy wires are oriented substantially parallel to the generated alternating magnetic field.Type: GrantFiled: October 25, 2012Date of Patent: August 28, 2018Assignee: The Boeing CompanyInventors: Noel T. Gerken, Robert James Miller, Jeffery L. Marcoe, John B. Moser, Aaron W. Bartel, Marc R. Matsen
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Patent number: 10016947Abstract: A fiber placement system including a fiber placement station at a first location, the fiber placement station including a tool and a fiber placement assembly configured to construct a reinforcement layup on the tool, the first fiber placement assembly including a compaction roller rotatable about an axis of rotation, the compaction roller at least partially defining a nip, a thermoplastic composite ply extending through the nip and a heating unit positioned to heat the thermoplastic composite ply proximate the nip, and a consolidation station at a consolidation location, the consolidation location being different from the first location, the consolidation station including a consolidation tool and a consolidation system configured to consolidate a reinforcement layup assembly that includes the reinforcement layup.Type: GrantFiled: May 21, 2015Date of Patent: July 10, 2018Assignee: The Boeing CompanyInventors: Marc R. Matsen, Mark A. Negley, Jeffery L. Marcoe, Stephen G. Moore, Brice A. Johnson, Alexandra K. Dillon, Megan M. Petersen
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Patent number: 9981421Abstract: Systems and processes that integrate thermoplastic and shape memory alloy materials to form an adaptive composite structure capable of changing its shape. For example, the adaptive composite structure may be designed to serve as a multifunctional adaptive wing flight control surface. Other applications for such adaptive composite structures include in variable area fan nozzles, winglets, fairings, elevators, rudders, or other aircraft components having an aerodynamic surface whose shape is preferably controllable. The material systems can be integrated by means of overbraiding (interwoven) with tows of both thermoplastic and shape memory alloy materials or separate layers of each material can be consolidated (e.g., using induction heating) to make a flight control surface that does not require separate actuation.Type: GrantFiled: July 16, 2014Date of Patent: May 29, 2018Assignee: The Boeing CompanyInventors: Jeffery L. Marcoe, Sahrudine Apdalhaliem, Moushumi Shome
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Patent number: 9981444Abstract: A composite stiffener is fabricated using preforms of laminated, unidirectional composite tape. The stiffener includes a void that is reinforced by a filler wrapped with a structural adhesive. The surfaces of the preforms surrounding the void include a layer of composite fabric which is bonded to the filler by the adhesive, thereby increasing the toughness of stiffeners around the void and improving pull-off strength of the stiffener.Type: GrantFiled: June 27, 2013Date of Patent: May 29, 2018Assignee: THE BOEING COMPANYInventors: Lyle R. Deobald, John D. Morris, Karl B. Lee, Jeffery L. Marcoe, Mark C. Iden, Christopher G. Harris
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Publication number: 20180065314Abstract: A radius filler includes a plurality of fibers encapsulated in resin and braided into a braided radius filler. The braided radius filler has a substantially triangular shape with concave radius filler side surfaces and a substantially planar radius filler base surface.Type: ApplicationFiled: October 30, 2017Publication date: March 8, 2018Inventors: Angelo Rossi, Jeffery L. Marcoe, Marc R. Matsen, Aaron W. Bartel, Waeil M. Ashmawi, Sahrudine Apdalhaliem, Adriana Willempje Blom-Schieber, David Reusch
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Patent number: 9827710Abstract: A method of manufacturing a radius filler may include providing a plurality of fibers, braiding the plurality of fibers into a braided preform, shaping the braided preform into a braided radius filler, and cutting the braided radius filler to a desired length.Type: GrantFiled: February 4, 2014Date of Patent: November 28, 2017Assignee: The Boeing CompanyInventors: Angelo Rossi, Jeffery L. Marcoe, Marc R. Matsen, Aaron W. Bartel
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Patent number: 9808996Abstract: In an embodiment of the disclosure, there is provided a method of fabricating a thermoplastic torque box assembly. The method includes providing a plurality of braided thermoplastic tubular spar caps, connecting one or more connector elements to one or more of the braided thermoplastic tubular spar caps, and laying up an inner thermoplastic facesheet in a continuous manner around the one or more braided thermoplastic tubular spar caps. The method further includes attaching a plurality of skin panel stabilization elements to the inner thermoplastic facesheet to define four torque box side portions, laying up and attaching an outer thermoplastic facesheet in a continuous manner around the plurality of skin panel stabilization elements, and heating at an effective temperature and an effective pressure the thermoplastic torque box assembly.Type: GrantFiled: August 26, 2014Date of Patent: November 7, 2017Assignee: The Boeing CompanyInventor: Jeffery L. Marcoe
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Publication number: 20170292547Abstract: Provided are assemblies having composite structures interlocked with shape memory alloy structures and methods of fabricating such assemblies. Interlocking may involve inserting an interlocking protrusion of a shape memory alloy structure into an interlocking opening of a composite structure and heating at least this protrusion of the shape memory alloy structure to activate the alloy and change the shape of the protrusion. This shape change engages the protrusion in the opening such that the protrusion cannot be removed from the opening. The shape memory alloy structure may be specifically trained prior to forming an assembly using a combination of thermal cycling and deformation to achieve specific pre-activation and post-activation shapes. The pre-activation shape allows inserting the interlocking protrusion into the opening, while the post-activation shape engages the interlocking protrusion within the opening. As such, activation of the shape memory alloy interlocks the two structures.Type: ApplicationFiled: June 22, 2017Publication date: October 12, 2017Applicant: The Boeing CompanyInventors: Waeil M. Ashmawi, Jaime C. Garcia, Sahrudine Apdalhaliem, Jeffery L. Marcoe, Moushumi Shome
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Patent number: 9719536Abstract: Provided are assemblies having composite structures interlocked with shape memory alloy structures and methods of fabricating such assemblies. Interlocking may involve inserting an interlocking protrusion of a shape memory alloy structure into an interlocking opening of a composite structure and heating at least this protrusion of the shape memory alloy structure to activate the alloy and change the shape of the protrusion. This shape change engages the protrusion in the opening such that the protrusion cannot be removed from the opening. The shape memory alloy structure may be specifically trained prior to forming an assembly using a combination of thermal cycling and deformation to achieve specific pre-activation and post-activation shapes. The pre-activation shape allows inserting the interlocking protrusion into the opening, while the post-activation shape engages the interlocking protrusion within the opening. As such, activation of the shape memory alloy interlocks the two structures.Type: GrantFiled: July 3, 2014Date of Patent: August 1, 2017Assignee: The Boeing CompanyInventors: Waeil M. Ashmawi, Jaime C. Garcia, Sahrudine Apdalhaliem, Jeffery L. Marcoe, Moushumi Shome
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Publication number: 20160339647Abstract: A fiber placement system including a fiber placement station at a first location, the fiber placement station including a tool and a fiber placement assembly configured to construct a reinforcement layup on the tool, the first fiber placement assembly including a compaction roller rotatable about an axis of rotation, the compaction roller at least partially defining a nip, a thermoplastic composite ply extending through the nip and a heating unit positioned to heat the thermoplastic composite ply proximate the nip, and a consolidation station at a consolidation location, the consolidation location being different from the first location, the consolidation station including a consolidation tool and a consolidation system configured to consolidate a reinforcement layup assembly that includes the reinforcement layup.Type: ApplicationFiled: May 21, 2015Publication date: November 24, 2016Inventors: Marc R. Matsen, Mark A. Negley, Jeffery L. Marcoe, Stephen G. Moore, Brice A. Johnson, Alexandra K. Dillon, Megan M. Petersen
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Publication number: 20160016355Abstract: Systems and processes that integrate thermoplastic and shape memory alloy materials to form an adaptive composite structure capable of changing its shape. For example, the adaptive composite structure may be designed to serve as a multifunctional adaptive wing flight control surface. Other applications for such adaptive composite structures include in variable area fan nozzles, winglets, fairings, elevators, rudders, or other aircraft components having an aerodynamic surface whose shape is preferably controllable. The material systems can be integrated by means of overbraiding (interwoven) with tows of both thermoplastic and shape memory alloy materials or separate layers of each material can be consolidated (e.g., using induction heating) to make a flight control surface that does not require separate actuation.Type: ApplicationFiled: July 16, 2014Publication date: January 21, 2016Applicant: THE BOEING COMPANYInventors: Jeffery L. Marcoe, Sahrudine Apdalhaliem, Moushumi Shome
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Publication number: 20160003280Abstract: Provided are assemblies having composite structures interlocked with shape memory alloy structures and methods of fabricating such assemblies. Interlocking may involve inserting an interlocking protrusion of a shape memory alloy structure into an interlocking opening of a composite structure and heating at least this protrusion of the shape memory alloy structure to activate the alloy and change the shape of the protrusion. This shape change engages the protrusion in the opening such that the protrusion cannot be removed from the opening. The shape memory alloy structure may be specifically trained prior to forming an assembly using a combination of thermal cycling and deformation to achieve specific pre-activation and post-activation shapes. The pre-activation shape allows inserting the interlocking protrusion into the opening, while the post-activation shape engages the interlocking protrusion within the opening. As such, activation of the shape memory alloy interlocks the two structures.Type: ApplicationFiled: July 3, 2014Publication date: January 7, 2016Applicant: The Boeing CompanyInventors: Waeil M. Ashmawi, Jaime C. Garcia, Sahrudine Apdalhaliem, Jeffery L. Marcoe, Moushumi Shome
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Patent number: 9174393Abstract: A method of fabricating a thermoplastic composite tubular structure provides a mandrel of a soluble, expandable material. The method overbraids the mandrel with a continuous fiber thermoplastic composite material to form an overbraided mandrel. The method installs the overbraided mandrel into a matched tooling assembly. The method heats in a heating apparatus the matched tooling assembly with the installed overbraided mandrel at a specified heating profile in order to consolidate the thermoplastic composite material and form a thermoplastic composite tubular structure. The method cools the matched tooling assembly with the formed thermoplastic composite tubular structure at a specified cooling profile. The method removes the formed thermoplastic composite tubular structure from the matched tooling assembly. The method solubilizes the mandrel to permanently remove the mandrel from the formed thermoplastic composite tubular structure.Type: GrantFiled: October 12, 2012Date of Patent: November 3, 2015Assignee: The Boeing CompanyInventors: Aaron W. Bartel, Brett I. Lyons, Jeffery L. Marcoe
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Publication number: 20150217508Abstract: A method of manufacturing a radius filler may include providing a plurality of fibers, braiding the plurality of fibers into a braided preform, shaping the braided preform into a braided radius filler, and cutting the braided radius filler to a desired length.Type: ApplicationFiled: February 4, 2014Publication date: August 6, 2015Applicant: The Boeing CompanyInventors: Angelo Rossi, Waeil M. Ashmawi, Sahrudine Apdalhaliem, Jeffery L. Marcoe, Marc R. Matsen, Aaron W. Bartel, Adriana Willempje Blom, David Reusch