Patents by Inventor Khanh Mai Pham
Khanh Mai Pham 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: 11820081Abstract: Systems and methods for assembling elongate composite structures are disclosed. The systems include a first rigid elongate cure tool defining a first elongate support surface for supporting a first elongate charge of composite material (FEC), a second rigid elongate cure tool defining a second elongate support surface for supporting a second elongate charge of composite material (SEC), and a flexible elongate caul plate. The systems further include a vacuum compaction film, a translation structure, and a vacuum source. Methods according to the present disclosure include positioning a vacuum compaction film, positioning a flexible elongate caul plate, and positioning an FEC. The methods further include positioning an SEC, contacting a region of the FEC with a region of the SEC, sealing the vacuum compaction film, evacuating the enclosed volume to generate an elongate composite assembly, and heating the elongate composite assembly to define the elongate composite structure.Type: GrantFiled: August 9, 2021Date of Patent: November 21, 2023Assignee: The Boeing CompanyInventors: Daniel M. Rotter, Brad A. Coxon, Gabriel Zane Forston, Jake Adam Reeves, Khanh Mai Pham, Stephen Lee Metschan, Patrick Shephard, John Dempsey Morris, Steven Philip Hansen, Brian Dodgson
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Patent number: 11806948Abstract: Systems and methods are provided for utilizing stringer end caps. One embodiment is a method of forming a stringer. The method includes laying up a stringer preform comprising fiber-reinforced material, placing the stringer preform onto a skin panel preform, bonding an end cap to the stringer preform and the skin panel preform, and co-curing the stringer preform and the skin panel preform while the end cap is bonded to the stringer preform and the skin panel preform, resulting in a composite part that includes the end cap.Type: GrantFiled: December 12, 2019Date of Patent: November 7, 2023Assignee: The Boeing CompanyInventors: Mary LeAnn Parker, Khanh Mai Pham, Lisa Christina Carlson, Garrett Charles Hanson
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Patent number: 11718047Abstract: Systems and methods are provided for fabricating composite parts. One embodiment is a method for fabricating a composite part. The method includes forming a skin panel preform comprising fiber reinforced material, disposing rigid end caps at the skin panel preform at end locations of stringer preforms that will be placed at the skin panel, locating the stringer preforms at the skin panel preform via the rigid end caps, and anchoring the stringer preforms to the skin panel preform.Type: GrantFiled: December 12, 2019Date of Patent: August 8, 2023Assignee: The Boeing CompanyInventors: Mary LeAnn Parker, Khanh Mai Pham, Lisa Christina Carlson, Garrett Charles Hanson
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Publication number: 20230219308Abstract: A method, apparatus, system, and computer program product for fabricating a composite part. Composite materials are laid up on a mandrel. A caul is placed over the composite materials laid up on the mandrel. An inner mold line of the caul is sized to an outer surface of the composite materials in a cured state. The composite materials laid up on the mandrel with the caul over the composite materials is cured to form the composite part. The composite materials expand to the inner mold line of the caul during curing of the composite materials to form the composite part.Type: ApplicationFiled: January 7, 2022Publication date: July 13, 2023Inventors: Mary LeAnn Parker, Khanh Mai Pham, Jonathan Santiago
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Patent number: 11660830Abstract: Aircraft that incorporates a rounded-hat composite stringer connected to an inner side of the skin of the aircraft to form an elongate conduit that defines a conduit axis, where the conduit axis includes at least one curving portion. The rounded-hat composite stringer can be manufactured by constructing a lower forming die and an upper forming die, each forming die having a length and defining a curve along at least a portion of the length of the die, cutting a pre-cured flat composite charge dimensioned to form the rounded-hat composite stringer, pressing the flat composite charge between the lower and upper forming dies to shape the composite charge into a pre-formed stringer having an inner side between curved fillet portions, contacting a forming member against the inner side of the pre-formed stringer, applying radius fillers to the curved fillet portions of the pre-formed stringer, curing the pre-formed stringer, and removing the forming member from the cured stringer.Type: GrantFiled: January 18, 2019Date of Patent: May 30, 2023Assignee: The Boeing CompanyInventors: Daniel Rotter, Lisa Carlson, Brad Andrew Coxon, Hyukbong Kwon, Khanh Mai Pham, Darrell D. Jones, Brian Robins
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Patent number: 11426958Abstract: Systems and methods are provided for composite part fabrication. One embodiment is a method for fabricating a composite part. The method includes selecting an end caul comprising a structure of sintered material surrounding volumes of unsintered particles, creating a laminate comprising fibers within a resin matrix, placing the end caul in contact with an end of the laminate, and processing the laminate.Type: GrantFiled: May 30, 2018Date of Patent: August 30, 2022Assignee: The Boeing CompanyInventors: Lisa Christina Carlson, Scott Allen Boner, Khanh Mai Pham, Mary Leann Parker, Alicia Salcedo Medina, John A. Minerich
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Patent number: 11426971Abstract: A composite structure including a composite body having an outer surface, wherein the composite body is elongated along a span axis, and a detection layer connected to the outer surface of the composite body, the detection layer including a plurality of strips, wherein each strip comprises a plurality of glass fibers embedded in a matrix material, is elongated along a detection axis, the detection axis being substantially aligned with the span axis, and is spaced a non-zero distance apart from adjacent strips such that a discontinuity is defined between adjacent strips.Type: GrantFiled: October 31, 2018Date of Patent: August 30, 2022Assignee: The Boeing CompanyInventors: Hyukbong Kwon, Khanh Mai Pham, Lisa C. Carlson, Garrett C. Hanson
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Publication number: 20210362481Abstract: Systems and methods for assembling elongate composite structures are disclosed. The systems include a first rigid elongate cure tool defining a first elongate support surface for supporting a first elongate charge of composite material (FEC), a second rigid elongate cure tool defining a second elongate support surface for supporting a second elongate charge of composite material (SEC), and a flexible elongate caul plate. The systems further include a vacuum compaction film, a translation structure, and a vacuum source. Methods according to the present disclosure include positioning a vacuum compaction film, positioning a flexible elongate caul plate, and positioning an FEC. The methods further include positioning an SEC, contacting a region of the FEC with a region of the SEC, sealing the vacuum compaction film, evacuating the enclosed volume to generate an elongate composite assembly, and heating the elongate composite assembly to define the elongate composite structure.Type: ApplicationFiled: August 9, 2021Publication date: November 25, 2021Inventors: Daniel M. Rotter, Brad A. Coxon, Gabriel Zane Forston, Jake Adam Reeves, Khanh Mai Pham, Stephen Lee Metschan, Patrick Shephard, John Dempsey Morris, Steven Philip Hansen, Brian Dodgson
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Patent number: 11104113Abstract: Systems and methods for assembling elongate composite structures are disclosed. The systems include a first rigid elongate cure tool defining a first elongate support surface for supporting a first elongate charge of composite material (FEC), a second rigid elongate cure tool defining a second elongate support surface for supporting a second elongate charge of composite material (SEC), and a flexible elongate caul plate. The systems further include a vacuum compaction film, a translation structure, and a vacuum source. Methods according to the present disclosure include positioning a vacuum compaction film, positioning a flexible elongate caul plate, and positioning an FEC. The methods further include positioning an SEC, contacting a region of the FEC with a region of the SEC, sealing the vacuum compaction film, evacuating the enclosed volume to generate an elongate composite assembly, and heating the elongate composite assembly to define the elongate composite structure.Type: GrantFiled: April 19, 2017Date of Patent: August 31, 2021Assignee: The Boeing CompanyInventors: Daniel M. Rotter, Brian Dodgson, Brad A. Coxon, Gabriel Zane Forston, Jake Adam Reeves, Khanh Mai Pham, Stephen Lee Metschan, Patrick Shephard, John Dempsey Morris, Steven Philip Hansen
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Publication number: 20210178706Abstract: Systems and methods are provided for fabricating composite parts. One embodiment is a method for fabricating a composite part. The method includes forming a skin panel preform comprising fiber reinforced material, disposing rigid end caps at the skin panel preform at end locations of stringer preforms that will be placed at the skin panel, locating the stringer preforms at the skin panel preform via the rigid end caps, and anchoring the stringer preforms to the skin panel preform.Type: ApplicationFiled: December 12, 2019Publication date: June 17, 2021Inventors: Mary LeAnn Parker, Khanh Mai Pham, Lisa Christina Carlson, Garrett Charles Hanson
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Publication number: 20210178708Abstract: Systems and methods are provided for utilizing stringer end caps. One embodiment is a method of forming a stringer. The method includes laying up a stringer preform comprising fiber-reinforced material, placing the stringer preform onto a skin panel preform, bonding an end cap to the stringer preform and the skin panel preform, and co-curing the stringer preform and the skin panel preform while the end cap is bonded to the stringer preform and the skin panel preform, resulting in a composite part that includes the end cap.Type: ApplicationFiled: December 12, 2019Publication date: June 17, 2021Inventors: Mary LeAnn Parker, Khanh Mai Pham, Lisa Christina Carlson, Garrett Charles Hanson
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Publication number: 20200282694Abstract: A composite structure that includes a multi-layer laminate including a plurality of layers of material, and at least one crack barrier layer extending within the plurality of layers of material. The multi-layer laminate is folded to define a first web region and a second web region in a face-to-face relationship, and a folded tip region defined between the first web region and the second web region. The at least one crack barrier layer is configured to restrict crack propagation from spreading through the plurality of layers of material in the folded tip region.Type: ApplicationFiled: March 7, 2019Publication date: September 10, 2020Inventors: Christopher Sanders, Hyukbong Kwon, Lisa Carlson, Khanh Mai Pham
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Publication number: 20200231267Abstract: Aircraft that incorporates a rounded-hat composite stringer connected to an inner side of the skin of the aircraft to form an elongate conduit that defines a conduit axis, where the conduit axis includes at least one curving portion. The rounded-hat composite stringer can be manufactured by constructing a lower forming die and an upper forming die, each forming die having a length and defining a curve along at least a portion of the length of the die, cutting a pre-cured flat composite charge dimensioned to form the rounded-hat composite stringer, pressing the flat composite charge between the lower and upper forming dies to shape the composite charge into a pre-formed stringer having an inner side between curved fillet portions, contacting a forming member against the inner side of the pre-formed stringer, applying radius fillers to the curved fillet portions of the pre-formed stringer, curing the pre-formed stringer, and removing the forming member from the cured stringer.Type: ApplicationFiled: January 18, 2019Publication date: July 23, 2020Applicant: The Boeing CompanyInventors: Daniel Rotter, Lisa Carlson, Brad Andrew Coxon, Hyukbong Kwon, Khanh Mai Pham, Darrell D. Jones, Brian Robins
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Patent number: 10661495Abstract: A method and apparatus is presented. Layers of composite material are laid down on a forming tool. A respective bend is formed in each of the layers to form the composite filler comprising bent layers on the forming tool. The composite filler comprising the bent layers is placed into a gap formed by at least one composite structure.Type: GrantFiled: January 19, 2017Date of Patent: May 26, 2020Assignee: The Boeing CompanyInventors: Michael R. Chapman, Khanh Mai Pham, Derek Paul Vetter
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Publication number: 20190366653Abstract: Systems and methods are provided for composite part fabrication. One embodiment is a method for fabricating a composite part. The method includes selecting an end caul comprising a structure of sintered material surrounding volumes of unsintered particles, creating a laminate comprising fibers within a resin matrix, placing the end caul in contact with an end of the laminate, and processing the laminate.Type: ApplicationFiled: May 30, 2018Publication date: December 5, 2019Inventors: Lisa Christina Carlson, Scott Allen Boner, Khanh Mai Pham, Mary LeAnn Parker, Alicia Salcedo Medina, John A. Minerich
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Publication number: 20190061310Abstract: A composite structure including a composite body having an outer surface and including a web portion having a proximal portion and a distal portion, and a base portion connected to the proximal portion of the web portion, wherein the composite body is elongated along a span axis, and a detection layer connected to the outer surface of the composite body at the distal portion of the web portion of the composite body, the detection layer including a plurality of glass fibers embedded in a first matrix material, wherein the composite body includes a plurality of carbon fibers embedded in a second matrix material, and wherein the outer surface of the composite body subjacent the detection layer is substantially free of exposed carbon fibers of the plurality of carbon fibers.Type: ApplicationFiled: October 31, 2018Publication date: February 28, 2019Applicant: The Boeing CompanyInventors: Hyukbong Kwon, Khanh Mai Pham, Lisa C. Carlson, Garrett C. Hanson
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Publication number: 20190061309Abstract: A composite structure including a composite body having an outer surface, wherein the composite body is elongated along a span axis, and a detection layer connected to the outer surface of the composite body, the detection layer including a plurality of strips, wherein each strip comprises a plurality of glass fibers embedded in a matrix material, is elongated along a detection axis, the detection axis being substantially aligned with the span axis, and is spaced a non-zero distance apart from adjacent strips such that a discontinuity is defined between adjacent strips.Type: ApplicationFiled: October 31, 2018Publication date: February 28, 2019Applicant: The Boeing CompanyInventors: Hyukbong Kwon, Khanh Mai Pham, Lisa C. Carlson, Garrett C. Hanson
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Publication number: 20180304606Abstract: Systems and methods for assembling elongate composite structures are disclosed. The systems include a first rigid elongate cure tool defining a first elongate support surface for supporting a first elongate charge of composite material (FEC), a second rigid elongate cure tool defining a second elongate support surface for supporting a second elongate charge of composite material (SEC), and a flexible elongate caul plate. The systems further include a vacuum compaction film, a translation structure, and a vacuum source. Methods according to the present disclosure include positioning a vacuum compaction film, positioning a flexible elongate caul plate, and positioning an FEC. The methods further include positioning an SEC, contacting a region of the FEC with a region of the SEC, sealing the vacuum compaction film, evacuating the enclosed volume to generate an elongate composite assembly, and heating the elongate composite assembly to define the elongate composite structure.Type: ApplicationFiled: April 19, 2017Publication date: October 25, 2018Inventors: Daniel M. Rotter, Brad A. Coxon, Gabriel Zane Forston, Jake Adam Reeves, Khanh Mai Pham, Stephen Lee Metschan, Patrick Shephard, John Dempsey Morris, Steven Philip Hansen, Brian Dodgson
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Publication number: 20170129192Abstract: A method and apparatus is presented. Layers of composite material are laid down on a forming tool. A respective bend is formed in each of the layers to form the composite filler comprising bent layers on the forming tool. The composite filler comprising the bent layers is placed into a gap formed by at least one composite structure.Type: ApplicationFiled: January 19, 2017Publication date: May 11, 2017Inventors: Michael R. Chapman, Khanh Mai Pham, Derek Paul Vetter
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Patent number: 9566739Abstract: A method and apparatus is presented. Layers of composite material are laid down on a forming tool. A respective bend is formed in each of the layers to form the composite filler comprising bent layers on the forming tool. The composite filler comprising the bent layers is placed into a gap formed by at least one composite structure.Type: GrantFiled: February 18, 2014Date of Patent: February 14, 2017Assignee: THE BOEING COMPANYInventors: Michael R. Chapman, Khanh Mai Pham, Derek Paul Vetter