Patents by Inventor Michael W. Hayes

Michael W. Hayes 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).

  • Patent number: 11529748
    Abstract: Methods, apparatus, and systems for cutting material used in fused deposition modeling systems are provided, which comprise a ribbon including one or more perforations. Material is passed through at least one perforation and movement of the ribbon cuts the material. A further embodiment comprises a disk including one or more blade structures, each forming at least one cavity. Material is passed through at least one cavity and a rotational movement of the disk cuts the material. A further embodiment comprises a slider-crank mechanism including a slider coupled to a set of parallel rails of a guide shaft. The slider moves along a length of the rails to cut the material. Yet another embodiment comprises one or more rotatable blade structures coupled to at least one rod. The rotation of the blade structures causes the blade structures to intersect and cut extruded material during each rotation.
    Type: Grant
    Filed: October 20, 2020
    Date of Patent: December 20, 2022
    Assignee: The Boeing Company
    Inventors: John C. Waldrop, III, Daniel D. Bloch, Michael W. Hayes, Loren J. Strahm, Peter A. Szostak
  • Patent number: 11390006
    Abstract: Provided are composite feedstock strips for additive manufacturing and methods of forming such strips. A composite feedstock strip may include continuous unidirectional fibers extending parallel to each other and to the principal axis of the strip. This fiber continuity yields superior mechanical properties, such as the tensile strength along strip's principal axis. Composite feedstock strips may be fabricated by slitting a composite laminate in a direction parallel to the fibers. In some embodiments, the cross-sectional shape of the slit strips may be changed by reattributing material at least on the surface of the strips and/or by coating the slit strips with another material. This cross-sectional shape change may be performed without disturbing the continuous fibers within the strips. The cross-sectional distribution of fibers within the strips may be uneven with higher concentration of fibers near the principal axis of the strips, for example, to assist with additive manufacturing.
    Type: Grant
    Filed: September 26, 2019
    Date of Patent: July 19, 2022
    Assignee: The Boeing Company
    Inventors: John C. Waldrop, III, Matthew S. Thompson, Michael W. Hayes, Stephen R. Heinz
  • Publication number: 20210031395
    Abstract: Methods, apparatus, and systems for cutting material used in fused deposition modeling systems are provided, which comprise a ribbon including one or more perforations. Material is passed through at least one perforation and movement of the ribbon cuts the material. A further embodiment comprises a disk including one or more blade structures, each forming at least one cavity. Material is passed through at least one cavity and a rotational movement of the disk cuts the material. A further embodiment comprises a slider-crank mechanism including a slider coupled to a set of parallel rails of a guide shaft. The slider moves along a length of the rails to cut the material. Yet another embodiment comprises one or more rotatable blade structures coupled to at least one rod. The rotation of the blade structures causes the blade structures to intersect and cut extruded material during each rotation.
    Type: Application
    Filed: October 20, 2020
    Publication date: February 4, 2021
    Applicant: The Boeing Company
    Inventors: John C. Waldrop, III, Daniel D. Bloch, Michael W. Hayes, Loren J. Strahm, Peter A. Szostak
  • Patent number: 10814511
    Abstract: Methods, apparatus, and systems for cutting material used in fused deposition modeling systems are provided, which comprise a ribbon including one or more perforations. Material is passed through at least one perforation and movement of the ribbon cuts the material. A further embodiment comprises a disk including one or more blade structures, each forming at least one cavity. Material is passed through at least one cavity and a rotational movement of the disk cuts the material. A further embodiment comprises a slider-crank mechanism including a slider coupled to a set of parallel rails of a guide shaft. The slider moves along a length of the rails to cut the material. Yet another embodiment comprises one or more rotatable blade structures coupled to at least one rod. The rotation of the blade structures causes the blade structures to intersect and cut extruded material during each rotation.
    Type: Grant
    Filed: December 10, 2018
    Date of Patent: October 27, 2020
    Assignee: The Boeing Company
    Inventors: John C. Waldrop, III, Daniel D. Bloch, Michael W. Hayes, Loren J. Strahm, Peter A. Szostak
  • Publication number: 20200016845
    Abstract: Provided are composite feedstock strips for additive manufacturing and methods of forming such strips. A composite feedstock strip may include continuous unidirectional fibers extending parallel to each other and to the principal axis of the strip. This fiber continuity yields superior mechanical properties, such as the tensile strength along strip's principal axis. Composite feedstock strips may be fabricated by slitting a composite laminate in a direction parallel to the fibers. In some embodiments, the cross-sectional shape of the slit strips may be changed by reattributing material at least on the surface of the strips and/or by coating the slit strips with another material. This cross-sectional shape change may be performed without disturbing the continuous fibers within the strips. The cross-sectional distribution of fibers within the strips may be uneven with higher concentration of fibers near the principal axis of the strips, for example, to assist with additive manufacturing.
    Type: Application
    Filed: September 26, 2019
    Publication date: January 16, 2020
    Applicant: The Boeing Company
    Inventors: John C. Waldrop, III, Matthew S. Thompson, Michael W. Hayes, Stephen R. Heinz
  • Patent number: 10464268
    Abstract: Provided are composite feedstock strips for additive manufacturing and methods of forming such strips. A composite feedstock strip may include continuous unidirectional fibers extending parallel to each other and to the principal axis of the strip. This fiber continuity yields superior mechanical properties, such as the tensile strength along strip's principal axis. Composite feedstock strips may be fabricated by slitting a composite laminate in a direction parallel to the fibers. In some embodiments, the cross-sectional shape of the slit strips may be changed by reattributing material at least on the surface of the strips and/or by coating the slit strips with another material. This cross-sectional shape change may be performed without disturbing the continuous fibers within the strips. The cross-sectional distribution of fibers within the strips may be uneven with higher concentration of fibers near the principal axis of the strips, for example, to assist with additive manufacturing.
    Type: Grant
    Filed: February 23, 2016
    Date of Patent: November 5, 2019
    Assignee: The Boeing Company
    Inventors: John C. Waldrop, III, Matthew S. Thompson, Michael W. Hayes, Stephen R. Heinz
  • Patent number: 10357924
    Abstract: Provided are composite feedstock strips for additive manufacturing and methods of forming such strips. A strip may include continuous fibers extending parallel to the principal axis of the strip. The cross-sectional distribution of these continuous fibers may be uneven. Specifically, the fibers may be concentrated near the center of the strip and may be positioned away from at least some portions of the strip surface. A strip may be formed by laminating a layup of one or more fiber-containing plies and one or more of resin plies. The position of the different types of plies in the layup is used to control distribution of the fibers and other materials within the strip. The laminated sheet is slit into multiple strips in a direction parallel to the continuous fibers. The cross-sectional profile of the slit strips may be later changed without disturbing orientation of the continuous fibers.
    Type: Grant
    Filed: August 25, 2015
    Date of Patent: July 23, 2019
    Assignee: The Boeing Company
    Inventors: John C. Waldrop, III, Michael W. Hayes, Gregory James Schoepen Hickman
  • Publication number: 20190105854
    Abstract: Methods, apparatus, and systems for cutting material used in fused deposition modeling systems are provided, which comprise a ribbon including one or more perforations. Material is passed through at least one perforation and movement of the ribbon cuts the material. A further embodiment comprises a disk including one or more blade structures, each forming at least one cavity. Material is passed through at least one cavity and a rotational movement of the disk cuts the material. A further embodiment comprises a slider-crank mechanism including a slider coupled to a set of parallel rails of a guide shaft. The slider moves along a length of the rails to cut the material. Yet another embodiment comprises one or more rotatable blade structures coupled to at least one rod. The rotation of the blade structures causes the blade structures to intersect and cut extruded material during each rotation.
    Type: Application
    Filed: December 10, 2018
    Publication date: April 11, 2019
    Applicant: The Boeing Company
    Inventors: John C. Waldrop, III, Daniel D. Bloch, Michael W. Hayes, Loren J. Strahm, Peter A. Szostak
  • Patent number: 10201940
    Abstract: A computer implemented apparatus and method for receiving tool paths that a dispensing head follows to deposit roads of material for successively building object layers of a 3D object during an additive manufacturing process, generating simulated object layers of a simulated 3D object from the tool paths, wherein the simulated object layers represent an interior geometry of each one of the object layers, determining a contact surface area between adjacent ones of the simulated object layers, and determining a predicted mechanical property of the 3D object from the contact surface area and a material property of the material.
    Type: Grant
    Filed: November 12, 2015
    Date of Patent: February 12, 2019
    Assignee: The Boeing Company
    Inventors: Michael W. Hayes, Loren J. Strahm, Nathanial C. Cuddy, Daniel E. Muntges
  • Patent number: 10150262
    Abstract: Methods, apparatus, and systems for cutting material used in fused deposition modeling systems are provided, which comprise a ribbon including one or more perforations. Material is passed through at least one perforation and movement of the ribbon cuts the material. A further embodiment comprises a disk including one or more blade structures, each forming at least one cavity. Material is passed through at least one cavity and a rotational movement of the disk cuts the material. A further embodiment comprises a slider-crank mechanism including a slider coupled to a set of parallel rails of a guide shaft. The slider moves along a length of the rails to cut the material. Yet another embodiment comprises one or more rotatable blade structures coupled to at least one rod. The rotation of the blade structures causes the blade structures to intersect and cut extruded material during each rotation.
    Type: Grant
    Filed: November 20, 2015
    Date of Patent: December 11, 2018
    Assignee: The Boeing Company
    Inventors: John C. Waldrop, III, Daniel D. Bloch, Michael W. Hayes, Loren J. Strahm, Peter A. Szostak
  • Patent number: 9732567
    Abstract: An interchangeable elevator bail link system and method for changing elevator bail length and load carrying configurations during rig operations, wherein an upper bail section is provided comprising a connection for a link tilt system of a top drive or traveling block, and further comprising a connector for connecting to a corresponding connector located on one or more lower bail sections of differing tonnage capacities and lengths, wherein the upper bail section connector and lower bail section connector comprise male and female profiles of corresponding size, shape and location, so that when the connector of the lower bail section is aligned in nonparallel relation to the connector of the upper bail section, which is attached to a link tilt system, movement of the top drive or traveling block in an upwards direction will cause the lower bail section to rotate to a position parallel with the upper bail section.
    Type: Grant
    Filed: July 28, 2015
    Date of Patent: August 15, 2017
    Assignee: H&H DRILLING TOOLS, LLC
    Inventor: Michael W. Hayes
  • Patent number: 9689783
    Abstract: A Z-axis test coupon structure and method for additive manufacturing process are disclosed. An example method of fabricating Z-axis test coupons for additive manufacturing processes, includes fabricating tensile specimens, the fabricating of the tensile specimens including providing a web between adjacent ones of the tensile specimens, and the fabricating of the tensile specimens including using an additive manufacturing process, removing the web from between the adjacent ones of the tensile specimens, and testing a tensile strength of one of the tensile specimens.
    Type: Grant
    Filed: July 9, 2015
    Date of Patent: June 27, 2017
    Assignee: The Boeing Company
    Inventors: David M. Dietrich, Michael W. Hayes
  • Publication number: 20170144375
    Abstract: Methods, apparatus, and systems for cutting material used in fused deposition modeling systems are provided, which comprise a ribbon including one or more perforations. Material is passed through at least one perforation and movement of the ribbon cuts the material. A further embodiment comprises a disk including one or more blade structures, each forming at least one cavity. Material is passed through at least one cavity and a rotational movement of the disk cuts the material. A further embodiment comprises a slider-crank mechanism including a slider coupled to a set of parallel rails of a guide shaft. The slider moves along a length of the rails to cut the material. Yet another embodiment comprises one or more rotatable blade structures coupled to at least one rod. The rotation of the blade structures causes the blade structures to intersect and cut extruded material during each rotation.
    Type: Application
    Filed: November 20, 2015
    Publication date: May 25, 2017
    Applicant: The Boeing Company
    Inventors: John C. Waldrop, III, Daniel D. Bloch, Michael W. Hayes, Loren J. Strahm, Peter A. Szostak
  • Publication number: 20170136703
    Abstract: A computer implemented apparatus and method for receiving tool paths that a dispensing head follows to deposit roads of material for successively building object layers of a 3D object during an additive manufacturing process, generating simulated object layers of a simulated 3D object from the tool paths, wherein the simulated object layers represent an interior geometry of each one of the object layers, determining a contact surface area between adjacent ones of the simulated object layers, and determining a predicted mechanical property of the 3D object from the contact surface area and a material property of the material.
    Type: Application
    Filed: November 12, 2015
    Publication date: May 18, 2017
    Inventors: Michael W. Hayes, Loren J. Strahm, Nathanial C. Cuddy, Daniel E Muntges
  • Publication number: 20170057181
    Abstract: Provided are composite feedstock strips for additive manufacturing and methods of forming such strips. A composite feedstock strip may include continuous unidirectional fibers extending parallel to each other and to the principal axis of the strip. This fiber continuity yields superior mechanical properties, such as the tensile strength along strip's principal axis. Composite feedstock strips may be fabricated by slitting a composite laminate in a direction parallel to the fibers. In some embodiments, the cross-sectional shape of the slit strips may be changed by reattributing material at least on the surface of the strips and/or by coating the slit strips with another material. This cross-sectional shape change may be performed without disturbing the continuous fibers within the strips. The cross-sectional distribution of fibers within the strips may be uneven with higher concentration of fibers near the principal axis of the strips, for example, to assist with additive manufacturing.
    Type: Application
    Filed: February 23, 2016
    Publication date: March 2, 2017
    Applicant: The Boeing Company
    Inventors: John C. Waldrop, III, Matthew S. Thompson, Michael W. Hayes, Stephen R. Heinz
  • Publication number: 20170057165
    Abstract: Provided are composite feedstock strips for additive manufacturing and methods of forming such strips. A strip may include continuous fibers extending parallel to the principal axis of the strip. The cross-sectional distribution of these continuous fibers may be uneven. Specifically, the fibers may be concentrated near the center of the strip and may be positioned away from at least some portions of the strip surface. A strip may be formed by laminating a layup of one or more fiber-containing plies and one or more of resin plies. The position of the different types of plies in the layup is used to control distribution of the fibers and other materials within the strip. The laminated sheet is slit into multiple strips in a direction parallel to the continuous fibers. The cross-sectional profile of the slit strips may be later changed without disturbing orientation of the continuous fibers.
    Type: Application
    Filed: August 25, 2015
    Publication date: March 2, 2017
    Applicant: The Boeing Company
    Inventors: John C. Waldrop, III, Michael W. Hayes, Gregory James Schoepen Hickman
  • Publication number: 20160115744
    Abstract: An interchangeable elevator bail link system and method for changing elevator bail length and load carrying configurations during rig operations, wherein an upper bail section is provided comprising a connection for a link tilt system of a top drive or traveling block, and further comprising a connector for connecting to a corresponding connector located on one or more lower bail sections of differing tonnage capacities and lengths, wherein the upper bail section connector and lower bail section connector comprise male and female profiles of corresponding size, shape and location, so that when the connector of the lower bail section is aligned in nonparallel relation to the connector of the upper bail section, which is attached to a link tilt system, movement of the top drive or traveling block in an upwards direction will cause the lower bail section to rotate to a position parallel with the upper bail section.
    Type: Application
    Filed: July 28, 2015
    Publication date: April 28, 2016
    Inventor: Michael W. HAYES
  • Patent number: 9303154
    Abstract: A vulcanizable composition of matter comprising a rubber component, a filler, a curative for the rubber, where the rubber component includes a multi-modal polymer including at least two distinct peak molecular weights within a range defined by a lower limit of 80 kg/mole and an upper limit of 500 kg/mole.
    Type: Grant
    Filed: December 28, 2009
    Date of Patent: April 5, 2016
    Assignee: Bridgestone Corporation
    Inventors: Zhong-Ren Chen, Kevin McCauley, Mark Smale, Michael W. Hayes, Steven Luo
  • Publication number: 20150308935
    Abstract: A Z-axis test coupon structure and method for additive manufacturing process are disclosed. An example method of fabricating Z-axis test coupons for additive manufacturing processes, includes fabricating tensile specimens, the fabricating of the tensile specimens including providing a web between adjacent ones of the tensile specimens, and the fabricating of the tensile specimens including using an additive manufacturing process, removing the web from between the adjacent ones of the tensile specimens, and testing a tensile strength of one of the tensile specimens.
    Type: Application
    Filed: July 9, 2015
    Publication date: October 29, 2015
    Inventors: David M. Dietrich, Michael W. Hayes
  • Patent number: 9109979
    Abstract: A Z-axis test coupon structure includes a plurality of circularly-arranged tensile specimens oriented along a Z-axis and at least one web connecting adjacent ones of the plurality of tensile specimens.
    Type: Grant
    Filed: May 3, 2010
    Date of Patent: August 18, 2015
    Assignee: THE BOEING COMPANY
    Inventors: David M. Dietrich, Michael W. Hayes