Patents by Inventor Kevin John Ford

Kevin John Ford 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).

  • Methods and systems for co-bonding or co-curing composite parts using a rigid/malleable SMP apparatus
    Patent number: 8951375
    Abstract: A method and apparatus for fabricating a composite part, such as a fuselage or internal stiffener, with a shape memory polymer (SMP) apparatus usable as both a rigid lay-up tool and a bladder. The SMP apparatus may be heated until malleable, shaped, and then cooled in a desired rigid tool configuration. For example, cavities may be formed into the SMP apparatus for nesting components therein to co-bond or co-cure with the composite part. Next, composite material may be applied onto the SMP apparatus and then placed into a rigid external tool and heated to composite cure temperatures at which the SMP apparatus is malleable. A pressure differential may be induced which urges the SMP apparatus to compress the composite material against the rigid external tool. When the composite material is cured, the SMP apparatus may be urged away from the cured composite material and removed from within the composite part.
    Type: Grant
    Filed: September 21, 2011
    Date of Patent: February 10, 2015
    Assignee: Spirit AeroSystems, Inc.
    Inventors: David E. Havens, Matthew C. Everhart, Randy Rex Kysar, Carl Ray Fiegenbaum, Jeffrey W. Priest, Delbert Leon Strelow, Kevin John Ford, Kristin Dru Pickell
  • Methods and systems for fabricating composite stiffeners with a rigid/malleable SMP apparatus
    Patent number: 8815145
    Abstract: A method and apparatus for fabricating a composite part with a shape memory polymer (SMP) apparatus usable as both a rigid tool and as a bladder. The SMP apparatus may be heated until malleable, shaped, and then cooled in a desired rigid tool configuration. The composite material may be applied onto the SMP apparatus and then placed into a rigid external mold and heated to composite cure temperatures at which the SMP apparatus is malleable. In some embodiments, an impermeable sheet of material may also be placed over portions of the composite material to compress it against the SMP apparatus. A pressure differential may be induced which urges the SMP apparatus to compress the composite material against the rigid external mold. When the composite material is cured, the pressure differential may be equalized and/or reversed and the malleable SMP apparatus may be removed from within the composite part.
    Type: Grant
    Filed: September 21, 2011
    Date of Patent: August 26, 2014
    Assignee: Spirit AeroSystems, Inc.
    Inventors: Matthew C. Everhart, David E. Havens, Joel James Everhart, Randy Rex Kysar, Carl Ray Fiegenbaum, Jeffrey W. Priest, Kevin John Ford, Delbert Leon Strelow
  • METHODS AND SYSTEMS FOR FABRICATING COMPOSITE STIFFENERS WITH A RIGID/MALLEABLE SMP APPARATUS
    Publication number: 20120286457
    Abstract: A method and apparatus for fabricating a composite part with a shape memory polymer (SMP) apparatus usable as both a rigid tool and as a bladder. The SMP apparatus may be heated until malleable, shaped, and then cooled in a desired rigid tool configuration. The composite material may be applied onto the SMP apparatus and then placed into a rigid external mold and heated to composite cure temperatures at which the SMP apparatus is malleable. In some embodiments, an impermeable sheet of material may also be placed over portions of the composite material to compress it against the SMP apparatus. A pressure differential may be induced which urges the SMP apparatus to compress the composite material against the rigid external mold. When the composite material is cured, the pressure differential may be equalized and/or reversed and the malleable SMP apparatus may be removed from within the composite part.
    Type: Application
    Filed: September 21, 2011
    Publication date: November 15, 2012
    Applicant: SPIRIT AEROSYSTEMS, INC.
    Inventors: Matthew C. Everhart, David E. Havens, Joel James Everhart, Randy Rex Kysar, Carl Ray Fiegenbaum, Jeffrey W. Priest, Kevin John Ford, Delbert Leon Strelow
  • METHODS AND SYSTEMS FOR CO-BONDING OR CO-CURING COMPOSITE PARTS USING A RIGID/MALLEABLE SMP APPARATUS
    Publication number: 20120118487
    Abstract: A method and apparatus for fabricating a composite part, such as a fuselage or internal stiffener, with a shape memory polymer (SMP) apparatus usable as both a rigid lay-up tool and a bladder. The SMP apparatus may be heated until malleable, shaped, and then cooled in a desired rigid tool configuration. For example, cavities may be formed into the SMP apparatus for nesting components therein to co-bond or co-cure with the composite part. Next, composite material may be applied onto the SMP apparatus and then placed into a rigid external tool and heated to composite cure temperatures at which the SMP apparatus is malleable. A pressure differential may be induced which urges the SMP apparatus to compress the composite material against the rigid external tool. When the composite material is cured, the SMP apparatus may be urged away from the cured composite material and removed from within the composite part.
    Type: Application
    Filed: September 21, 2011
    Publication date: May 17, 2012
    Applicant: SPIRIT AEROSYSTEMS, INC.
    Inventors: David E. Havens, Matthew C. Everhart, Randy Rex Kysar, Carl Ray Fiegenbaum, Jeffrey W. Priest, Delbert Leon Strelow, Kevin John Ford, Kristin Dru Pickell