Patents by Inventor Michael Palmore Matlack
Michael Palmore Matlack 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: 11633931Abstract: A method and apparatus for a continuous compression molding machine. The continuous compression molding machine comprises a tooling die, extending through a heating zone and a cooling zone, a tooling sleeve, and a biasing system. The tooling sleeve corresponds to the tooling die and is for use in forming a thermoplastic composite part from a thermoplastic composite charge when the tooling sleeve with the thermoplastic composite charge is moved with respect to the tooling die through the heating zone and the cooling zone. The biasing system is configured to hold the thermoplastic charge at a first angle within the heating zone and hold the thermoplastic composite charge at a second angle within the cooling zone, as the tooling sleeve moves through the heating zone and the cooling zone with the thermoplastic composite charge. The first angle is different from the second angle.Type: GrantFiled: August 13, 2020Date of Patent: April 25, 2023Assignee: The Boeing CompanyInventors: Philip P. Steinacher, Randall Dow Wilkerson, James Rodney Fox, Michael Palmore Matlack, Ryan Joseph Merriman, Donald C. Besselsen, David Phillip Bruk
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Patent number: 11485096Abstract: A composite manufacturing system and method are provided. The composite manufacturing system comprises a press and a bladder. The press has an upper portion having a desired shape for a composite structure and a lower portion configured to receive layers of composite material. The bladder is associated with the upper portion of the press and is configured to reach a superplastic state when heated such that the bladder forms to the composite structure by applying heat and pressure to the layers of composite material. The bladder cools without appreciable shrinkage, applying a desired amount of pressure to the composite structure during the entire cooling cycle. Once one composite structure is formed using the bladder, the bladder may be reused to form similar structures.Type: GrantFiled: May 17, 2019Date of Patent: November 1, 2022Assignee: The Boeing CompanyInventors: Steven M. Shewchuk, Justin Joseph Schell, Michael Palmore Matlack, Ravi Verma
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Patent number: 10940656Abstract: A press tool for a press assembly includes an additive manufactured body including a plurality of stacked layers of additive manufacturable material extending between an interior side and an exterior side. The interior side has a part forming surface including a surface profile for forming a part. The exterior side has a plurality of hollow cores defined by longitudinal walls and lateral walls meeting at joints. Press inserts are coupled to the longitudinal walls and the lateral walls at the exterior side. The press inserts are configured to be pressed inward by a pressing load during a pressing operation for forming the part. The press inserts distribute the pressing load along the longitudinal and lateral walls.Type: GrantFiled: May 31, 2017Date of Patent: March 9, 2021Assignee: THE BOEING COMPANYInventors: Michael Palmore Matlack, Steven Michael Shewchuk
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Publication number: 20200368945Abstract: A method and apparatus for a continuous compression molding machine. The continuous compression molding machine comprises a tooling die, extending through a heating zone and a cooling zone, a tooling sleeve, and a biasing system. The tooling sleeve corresponds to the tooling die and is for use in forming a thermoplastic composite part from a thermoplastic composite charge when the tooling sleeve with the thermoplastic composite charge is moved with respect to the tooling die through the heating zone and the cooling zone. The biasing system is configured to hold the thermoplastic charge at a first angle within the heating zone and hold the thermoplastic composite charge at a second angle within the cooling zone, as the tooling sleeve moves through the heating zone and the cooling zone with the thermoplastic composite charge. The first angle is different from the second angle.Type: ApplicationFiled: August 13, 2020Publication date: November 26, 2020Inventors: Philip P. Steinacher, Randall Dow Wilkerson, James Rodney Fox, Michael Palmore Matlack, Ryan Joseph Merriman, Donald C. Besselsen, David Phillip Bruk
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Publication number: 20200361162Abstract: A composite manufacturing system and method are provided. The composite manufacturing system comprises a press and a bladder. The press has an upper portion having a desired shape for a composite structure and a lower portion configured to receive layers of composite material. The bladder is associated with the upper portion of the press and is configured to reach a superplastic state when heated such that the bladder forms to the composite structure by applying heat and pressure to the layers of composite material. The bladder cools without appreciable shrinkage, applying a desired amount of pressure to the composite structure during the entire cooling cycle. Once one composite structure is formed using the bladder, the bladder may be reused to form similar structures.Type: ApplicationFiled: May 17, 2019Publication date: November 19, 2020Inventors: Steven M. Shewchuk, Justin Joseph Schell, Michael Palmore Matlack, Ravi Verma
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Patent number: 10773430Abstract: A method and apparatus for a continuous compression molding machine. The continuous compression molding machine comprises a tooling die, extending through a heating zone and a cooling zone, a tooling sleeve, and a biasing system. The tooling sleeve corresponds to the tooling die and is for use in forming a thermoplastic composite part from a thermoplastic composite charge when the tooling sleeve with the thermoplastic composite charge is moved with respect to the tooling die through the heating zone and the cooling zone. The biasing system is configured to hold the thermoplastic charge at a first angle within the heating zone and hold the thermoplastic composite charge at a second angle within the cooling zone, as the tooling sleeve moves through the heating zone and the cooling zone with the thermoplastic composite charge. The first angle is different from the second angle.Type: GrantFiled: April 25, 2017Date of Patent: September 15, 2020Assignee: The Boeing CompanyInventors: Philip P. Steinacher, Randall Dow Wilkerson, James Rodney Fox, Michael Palmore Matlack, Ryan Joseph Merriman, Donald C. Besselsen, David Phillip Bruk
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Patent number: 10751955Abstract: A method and apparatus for a composite structure manufacturing system. The system comprises a heating system and one or more smart bladders that encompass the heating system. The heating system and the one or more smart bladders form a curing tool defining a volume for the composite structure when one or more smart bladders in the one or more smart bladders is in a rigid state.Type: GrantFiled: April 10, 2017Date of Patent: August 25, 2020Assignee: The Boeing CompanyInventors: Zeaid F. Hasan, Michael Palmore Matlack, Emily E. McDonald
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Patent number: 10392131Abstract: A tool assembly includes a support frame including support beams and support mounts supporting the support beams. The support frame is rigid and used to transport the tool assembly. A support tool is supported by the support frame and includes a faceplate and a supporting grid structure formed with the faceplate as a monolithic structure defined by a series of AM layers. The faceplate has a supporting surface at a top of the support tool for supporting a working component. The supporting grid structure engages the support beams such that loads are transferred between the support tool and the support frame through the support beams. The support frame maintains dimensional stability of the support tool during transport and when resting within an allowable tolerance of the support tool.Type: GrantFiled: October 21, 2016Date of Patent: August 27, 2019Assignee: The Boeing CompanyInventors: Eric Eldon Deck, Michael Palmore Matlack
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Publication number: 20180345616Abstract: A press tool for a press assembly includes an additive manufactured body including a plurality of stacked layers of additive manufacturable material extending between an interior side and an exterior side. The interior side has a part forming surface including a surface profile for forming a part. The exterior side has a plurality of hollow cores defined by longitudinal walls and lateral walls meeting at joints. Press inserts are coupled to the longitudinal walls and the lateral walls at the exterior side. The press inserts are configured to be pressed inward by a pressing load during a pressing operation for forming the part. The press inserts distribute the pressing load along the longitudinal and lateral walls.Type: ApplicationFiled: May 31, 2017Publication date: December 6, 2018Applicant: THE BOEING COMPANYInventors: Michael Palmore Matlack, Steven Michael Shewchuk
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Publication number: 20180304503Abstract: A method and apparatus for a continuous compression molding machine. The continuous compression molding machine comprises a tooling die, extending through a heating zone and a cooling zone, a tooling sleeve, and a biasing system. The tooling sleeve corresponds to the tooling die and is for use in forming a thermoplastic composite part from a thermoplastic composite charge when the tooling sleeve with the thermoplastic composite charge is moved with respect to the tooling die through the heating zone and the cooling zone. The biasing system is configured to hold the thermoplastic charge at a first angle within the heating zone and hold the thermoplastic composite charge at a second angle within the cooling zone, as the tooling sleeve moves through the heating zone and the cooling zone with the thermoplastic composite charge. The first angle is different from the second angle.Type: ApplicationFiled: April 25, 2017Publication date: October 25, 2018Inventors: Philip P. Steinacher, Randall Dow Wilkerson, James Rodney Fox, Michael Palmore Matlack, Ryan Joseph Merriman, Donald C. Besselsen, David Phillip Bruk
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Publication number: 20180290403Abstract: A method and apparatus for a composite structure manufacturing system. The system comprises a heating system and one or more smart bladders that encompass the heating system. The heating system and the one or more smart bladders form a curing tool defining a volume for the composite structure when one or more smart bladders in the one or more smart bladders is in a rigid state.Type: ApplicationFiled: April 10, 2017Publication date: October 11, 2018Inventors: Zeaid F. Hasan, Michael Palmore Matlack, Emily E. McDonald
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Publication number: 20180057188Abstract: A tool assembly includes a support frame including support beams and support mounts supporting the support beams. The support frame is rigid and used to transport the tool assembly. A support tool is supported by the support frame and includes a faceplate and a supporting grid structure formed with the faceplate as a monolithic structure defined by a series of AM layers. The faceplate has a supporting surface at a top of the support tool for supporting a working component. The supporting grid structure engages the support beams such that loads are transferred between the support tool and the support frame through the support beams. The support frame maintains dimensional stability of the support tool during transport and when resting within an allowable tolerance of the support tool.Type: ApplicationFiled: October 21, 2016Publication date: March 1, 2018Applicant: THE BOEING COMPANYInventors: Eric Eldon Deck, Michael Palmore Matlack