Patents by Inventor Mark W. Costa

Mark W. Costa 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).

  • Publication number: 20240140083
    Abstract: A method for preparing an abradable panel for a rub strip of a fan case of a gas turbine engine includes forming an abradable material into a plurality of panels each comprising an abradable structure; curing the abradable material in the plurality of panels; and installing the plurality of panels into the fan case. The panels can be cured and assembled into a fully assembled rubstrip, and then the assembled rubstrip can be installed into the fan case.
    Type: Application
    Filed: October 28, 2022
    Publication date: May 2, 2024
    Applicant: Raytheon Technologies Corporation
    Inventors: Kerry E. Muenchow, Georgios S. Zafiris, John Harner, Raymond P. Martina, Jr., Imad Hanhan, Darin S. Lussier, Mark W. Costa, Michael R. LaFavor, Scott A. Smith
  • Patent number: 11939871
    Abstract: An abradable material for a rub strip of a gas turbine engine component includes a polymer matrix, and an organic or inorganic filler distributed through the matrix, wherein the abradable material has a compression spring rate profile including: less than 50,000 lb/in at ?65° F., less than 35,000 lb/in at room temperature, and less than 35,000 lb/in at 200° F.
    Type: Grant
    Filed: October 28, 2022
    Date of Patent: March 26, 2024
    Assignee: RTX Corporation
    Inventors: Kerry E. Muenchow, Georgios S. Zafiris, Raymond P. Martina, Jr., John Harner, Imad Hanhan, Darin S. Lussier, Scott A. Smith, Mark W. Costa, Michael R. LaFavor
  • Patent number: 11236769
    Abstract: In a fan case having an annular outer wall with a plurality of fan case bolt holes there through, bushings are inserted into the fan case bolt hole and are dimensioned to define an annular gap between the bolt hole inner surface and the bushing outer surface. An adhesive material disposed within each annular gap between the bushing and the corresponding fan case bolt hole, with the adhesive material forming a liquid shim separating the bushing outer surface from the bolt hole inner surface.
    Type: Grant
    Filed: August 29, 2019
    Date of Patent: February 1, 2022
    Assignee: RAYTHEON TECHNOLOGIES CORPORATION
    Inventors: Thomas J. Robertson, Mark W. Costa
  • Patent number: 10731511
    Abstract: A blade containment system includes a plurality of circumferentially-arranged rotatable blades. Each blade has a blade compliance. An annular containment structure is arranged around the rotatable blades. The containment structure includes a liner that has a liner compliance. The blade compliance and the liner compliance are configured such that a strain induced on a respective one of the blades upon impact with the liner is less than a threshold critical strain beyond which the rotatable blades fracture.
    Type: Grant
    Filed: February 22, 2013
    Date of Patent: August 4, 2020
    Assignee: RAYTHEON TECHNOLOGIES CORPORATION
    Inventors: Thomas J. Robertson, Jr., Sreenivasa R. Voleti, Mark W. Costa, Steven Clarkson
  • Patent number: 10724403
    Abstract: A fan case assembly for a gas turbine engine includes a honeycomb structure. The fan case assembly also includes a septum operatively coupled to the honeycomb structure and located radially inward of the honeycomb structure. The fan case assembly further includes a rubstrip in contact with the septum and located radially inward of the septum.
    Type: Grant
    Filed: July 16, 2018
    Date of Patent: July 28, 2020
    Assignee: RAYTHEON TECHNOLOGIES CORPORATION
    Inventor: Mark W. Costa
  • Patent number: 10669936
    Abstract: A cartridge for a fan case of a gas turbine engine includes an inlet acoustic liner section integrated with a thermally conforming liner section.
    Type: Grant
    Filed: March 12, 2014
    Date of Patent: June 2, 2020
    Assignee: Raytheon Technologies Corporation
    Inventors: Thomas J. Robertson, Jr., Mark W. Costa, David A. Welch
  • Publication number: 20200018185
    Abstract: A fan case assembly for a gas turbine engine includes a honeycomb structure. The fan case assembly also includes a septum operatively coupled to the honeycomb structure and located radially inward of the honeycomb structure. The fan case assembly further includes a rubstrip in contact with the septum and located radially inward of the septum.
    Type: Application
    Filed: July 16, 2018
    Publication date: January 16, 2020
    Inventor: Mark W. Costa
  • Patent number: 10533450
    Abstract: A gas turbine engine is provided. The gas turbine engine comprising: a fan section having a fan; and a containment zone encircling the fan, the containment zone comprising: a ballistic liner composed of a plurality of ring segments located radially outward of the fan; wherein each of the plurality of ring segments include two opposing circumferential ends, and wherein the plurality of ring segments are arranged circumferentially around the fan section and the circumferential ends of each of the plurality of ring segments meet at joints to form the ballistic liner.
    Type: Grant
    Filed: October 30, 2017
    Date of Patent: January 14, 2020
    Assignee: UNITED TECHNOLOGIES CORPORATION
    Inventors: Colin J. Kling, Darin S. Lussier, Mark W. Costa
  • Publication number: 20200011348
    Abstract: In a fan case having an annular outer wall with a plurality of fan case bolt holes there through, bushings are inserted into the fan case bolt hole and are dimensioned to define an annular gap between the bolt hole inner surface and the bushing outer surface. An adhesive material disposed within each annular gap between the bushing and the corresponding fan case bolt hole, with the adhesive material forming a liquid shim separating the bushing outer surface from the bolt hole inner surface.
    Type: Application
    Filed: August 29, 2019
    Publication date: January 9, 2020
    Inventors: Thomas J. Robertson, Mark W. Costa
  • Patent number: 10502235
    Abstract: In a fan case having an annular outer wall with a plurality of fan case bolt holes there through, bushings are inserted into the fan case bolt hole and are dimensioned to define an annular gap between the bolt hole inner surface and the bushing outer surface. An adhesive material disposed within each annular gap between the bushing and the corresponding fan case bolt hole, with the adhesive material forming a liquid shim separating the bushing outer surface from the bolt hole inner surface.
    Type: Grant
    Filed: August 22, 2014
    Date of Patent: December 10, 2019
    Assignee: UNITED TECHNOLOGIES CORPORATION
    Inventors: Thomas J. Robertson, Mark W. Costa
  • Patent number: 10487693
    Abstract: A method for installing a mounting hole through a wall of a fan case of a gas turbine engine is disclosed. The method may comprise: 1) installing a pilot hole through the wall of the fan case at an angle perpendicular to an outer surface of the wall, 2) inserting a boss through the pilot hole, 3) bonding the boss to the wall of the fan case, and 4) installing the mounting hole through the boss at an off-axis angle with respect to the angle perpendicular to the outer surface of the wall.
    Type: Grant
    Filed: February 5, 2018
    Date of Patent: November 26, 2019
    Assignee: UNITED TECHNOLOGIES CORPORATION
    Inventors: Thomas J. Robertson, Jr., Mark W. Costa, Steven Clarkson
  • Patent number: 10480530
    Abstract: A fan section for a gas turbine engine according to an example of the present disclosure includes, among other things, a fan containment case assembly that has an outer case extending about an axis, and a thermally conforming liner assembly radially inward of the outer case. The liner assembly has a shell, a wrap radially outward of the shell, and a ballistic liner between the outer case and the wrap. The wrap has a first fiber construction, and the ballistic liner has a second fiber construction that differs from the first fiber construction in stiffness.
    Type: Grant
    Filed: August 25, 2017
    Date of Patent: November 19, 2019
    Assignee: UNITED TECHNOLOGIES CORPORATION
    Inventor: Mark W. Costa
  • Patent number: 10436612
    Abstract: A capacitance probe monitors the distance between a blade tip and a fan, compressor or turbine case. The capacitance probe may be attached to a liner, and may travel with the liner as it radially expands due to thermal changes. The capacitance probe may include a circuit board sensor with a metallic plate, and one or more capacitors. The metallic plate may be encapsulated within an insulating material. A plurality of soft leads may be in electrical communication with the circuit board sensor, allowing a lower lead weight, reduced size and increased flexibility. The soft leads may also be embedded in the liner. In this way, the capacitance probe can record more accurate distance measurements and promote a gas turbine engine's continued and efficient operation.
    Type: Grant
    Filed: October 21, 2015
    Date of Patent: October 8, 2019
    Assignee: UNITED TECHNOLOGIES CORPORATION
    Inventors: Kevin Ford, Eli Warren, Corey A. Benoit, Edward F Dreger, Erik D. Rice, Mark W. Costa
  • Publication number: 20190128136
    Abstract: A gas turbine engine is provided. The gas turbine engine comprising: a fan section having a fan; and a containment zone encircling the fan, the containment zone comprising: a ballistic liner composed of a plurality of ring segments located radially outward of the fan; wherein each of the plurality of ring segments include two opposing circumferential ends, and wherein the plurality of ring segments are arranged circumferentially around the fan section and the circumferential ends of each of the plurality of ring segments meet at joints to form the ballistic liner.
    Type: Application
    Filed: October 30, 2017
    Publication date: May 2, 2019
    Inventors: Colin J. Kling, Darin S. Lussier, Mark W. Costa
  • Publication number: 20190063460
    Abstract: A fan section for a gas turbine engine according to an example of the present disclosure includes, among other things, a fan containment case assembly that has an outer case extending about an axis, and a thermally conforming liner assembly radially inward of the outer case. The liner assembly has a shell, a wrap radially outward of the shell, and a ballistic liner between the outer case and the wrap. The wrap has a first fiber construction, and the ballistic liner has a second fiber construction that differs from the first fiber construction in stiffness.
    Type: Application
    Filed: August 25, 2017
    Publication date: February 28, 2019
    Inventor: Mark W. Costa
  • Publication number: 20180171826
    Abstract: A method for installing a mounting hole through a wall of a fan case of a gas turbine engine is disclosed. The method may comprise: 1) installing a pilot hole through the wall of the fan case at an angle perpendicular to an outer surface of the wall, 2) inserting a boss through the pilot hole, 3) bonding the boss to the wall of the fan case, and 4) installing the mounting hole through the boss at an off-axis angle with respect to the angle perpendicular to the outer surface of the wall.
    Type: Application
    Filed: February 5, 2018
    Publication date: June 21, 2018
    Inventors: Thomas J. Robertson, JR., Mark W. Costa, Steven Clarkson
  • Patent number: 9982605
    Abstract: A mount for mounting a component to a gas turbine engine is disclosed. The mount may include a central portion that attaches to the component, and a flange circumscribing the central portion and extending to the gas turbine engine, the flange including a fusible region that breaks at a predetermined load. A method for protecting a component mounted to a gas turbine engine is also disclosed. The method may include attaching a mount to a casing of the gas turbine engine, the mount including a fusible region that breaks at a predetermined load. The method may further include attaching the component to the mount. The method may further include the fusible region breaking when the mount experiences the predetermined load, detaching the component from the casing of the gas turbine engine.
    Type: Grant
    Filed: September 13, 2013
    Date of Patent: May 29, 2018
    Assignee: UNITED TECHNOLOGIES CORPORATION
    Inventors: Thomas J. Robertson, Steven Clarkson, Mark w. Costa
  • Patent number: 9909458
    Abstract: A method for installing a mounting hole through a wall of a fan case of a gas turbine engine is disclosed. The method may comprise: 1) installing a pilot hole through the wall of the fan case at an angle perpendicular to an outer surface of the wall, 2) inserting a boss through the pilot hole, 3) bonding the boss to the wall of the fan case, and 4) installing the mounting hole through the boss at an off-axis angle with respect to the angle perpendicular to the outer surface of the wall.
    Type: Grant
    Filed: February 4, 2015
    Date of Patent: March 6, 2018
    Assignee: UNITED TECHNOLOGIES CORPORATION
    Inventors: Thomas J. Robertson, Jr., Mark W. Costa, Steven Clarkson
  • Patent number: 9702375
    Abstract: A gas turbine engine includes a liner disposed around a flowpath. The liner has a forward end, a radially outer surface, and a radially inner surface. A hole extends axially into the forward end of the liner between the radially outer surface and the radially inner surface, and an engagement member is partially disposed in the hole and extends axially forward from the forward end of the liner.
    Type: Grant
    Filed: July 2, 2014
    Date of Patent: July 11, 2017
    Assignee: United Technologies Corporation
    Inventors: Mark W. Costa, Thomas J. Robertson, Jr., David A. Welch
  • Patent number: 9482111
    Abstract: A fan section of a gas turbine engine includes a fan containment case assembly includes an outer case of an aluminum alloy. The outer case extends circumferentially around an axial centerline. A thermally conforming liner assembly is located inwardly of the outer case. The thermally conforming liner assembly includes a circumferential liner of an aluminum alloy. A ballistic liner is located between the outer case and the thermally conforming liner assembly.
    Type: Grant
    Filed: December 14, 2012
    Date of Patent: November 1, 2016
    Assignee: United Technologies Corporation
    Inventors: Mark W. Costa, Thomas J. Robertson, Jr., Darin S. Lussier