Patents by Inventor Mike P. Matlack
Mike P. 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: 11214020Abstract: This disclosure is directed to a thermoplastic composite material forming method and tooling used to perform the method. More specifically, this disclosure is directed to a method of fabricating large, complex thermoplastic composite part shapes with a consolidation tool having a conformable tooling bladder that heat thermoplastic material in the tool and provide thermoplastic material consolidation pressure in directions in the tool to form a part shape of thermoplastic composite material. A novel tooling concept is used to fabricate large, complex thermoplastic composite part shapes which are not easily producible using traditional methods.Type: GrantFiled: August 27, 2019Date of Patent: January 4, 2022Assignee: The Boeing CompanyInventors: Mike P. Matlack, Alexander M. Rubin, Randall D. Wilkerson, Amol Ogale
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Publication number: 20210060873Abstract: This disclosure is directed to a thermoplastic composite material forming method and tooling used to perform the method. More specifically, this disclosure is directed to a method of fabricating large, complex thermoplastic composite part shapes with a consolidation tool having a conformable tooling bladder that heat thermoplastic material in the tool and provide thermoplastic material consolidation pressure in directions in the tool to form a part shape of thermoplastic composite material. A novel tooling concept is used to fabricate large, complex thermoplastic composite part shapes which are not easily producible using traditional methods.Type: ApplicationFiled: August 27, 2019Publication date: March 4, 2021Applicant: The Boeing CompanyInventors: Mike P. Matlack, Alexander M. Rubin, Randall D. Wilkerson, Amol Ogale
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Patent number: 10232571Abstract: A system and method for forming an item from a material, which may include elongated fibers and/or stretched broken fibers. The material is placed on a first clamping portion, which is placed on a fixture. A second clamping portion is placed against the material and the first clamping portion and secured together, forming a clamping assembly. The clamping assembly is removed from the fixture and placed on a first die portion, having a first profile. A second die portion is also provided, having a second profile. In forming the item, at least one of the first die portion and the second die portion are moved toward each other such that a second surface of the first die portion and a first surface of the second die portion contact and form the material into the item generally replicating the first profile and the second profile.Type: GrantFiled: September 22, 2015Date of Patent: March 19, 2019Assignee: the boeing companyInventors: Mike P. Matlack, Stephen J. Morgan, Thomas K. Tsotsis, James R. Fox, Randall D. Wilkerson
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Patent number: 10226905Abstract: A system and method for forming an item from a material, which may include elongated fibers and/or stretched broken fibers. The material is placed on a first clamping portion, which is placed on a fixture. A second clamping portion is placed against the material and the first clamping portion and secured together, forming a clamping assembly. The clamping assembly is removed from the fixture and placed on a first die portion, having a first profile. A second die portion is also provided, having a second profile. In forming the item, at least one of the first die portion and the second die portion are moved toward each other such that a second surface of the first die portion and a first surface of the second die portion contact and form the material into the item generally replicating the first profile and the second profile.Type: GrantFiled: September 22, 2015Date of Patent: March 12, 2019Assignee: the boeing companyInventors: Mike P. Matlack, Stephen J. Morgan, Thomas K. Tsotsis, James R. Fox, Randall D. Wilkerson
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Patent number: 9687935Abstract: One example of the present disclosure relates to a method of processing first and second workpieces. The method includes constraining the second workpiece; abutting first and second workpieces together to form a joint; applying first and second selectively adjustable forces against the first workpiece to bias the first workpiece against the second workpiece; friction stir welding the first and second workpieces along the joint; maintaining the forces equal to each other while friction stir welding; and automatically varying at least one of the forces responsive to thermal size variations of the first and second workpieces. An apparatus for carrying out this method is also provided.Type: GrantFiled: November 18, 2015Date of Patent: June 27, 2017Assignee: THE BOEING COMPANYInventors: Mike P. Matlack, Kurt A. Burton, John A. Baumann
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Publication number: 20170080650Abstract: A system and method for forming an item from a material, which may include elongated fibers and/or stretched broken fibers. The material is placed on a first clamping portion, which is placed on a fixture. A second clamping portion is placed against the material and the first clamping portion and secured together, forming a clamping assembly. The clamping assembly is removed from the fixture and placed on a first die portion, having a first profile. A second die portion is also provided, having a second profile. In forming the item, at least one of the first die portion and the second die portion are moved toward each other such that a second surface of the first die portion and a first surface of the second die portion contact and form the material into the item generally replicating the first profile and the second profile.Type: ApplicationFiled: September 22, 2015Publication date: March 23, 2017Inventors: Mike P. Matlack, Stephen J. Morgan, Thomas K. Tsotsis, James R. Fox, Randall D. Wilkerson
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Publication number: 20170080651Abstract: A system and method for forming an item from a material, which may include elongated fibers and/or stretched broken fibers. The material is placed on a first clamping portion, which is placed on a fixture. A second clamping portion is placed against the material and the first clamping portion and secured together, forming a clamping assembly. The clamping assembly is removed from the fixture and placed on a first die portion, having a first profile. A second die portion is also provided, having a second profile. In forming the item, at least one of the first die portion and the second die portion are moved toward each other such that a second surface of the first die portion and a first surface of the second die portion contact and form the material into the item generally replicating the first profile and the second profile.Type: ApplicationFiled: September 22, 2015Publication date: March 23, 2017Inventors: Mike P. Matlack, Stephen J. Morgan, Thomas K. Tsotsis, James R. Fox, Randall D. Wilkerson
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Patent number: 9511461Abstract: A manufacturing apparatus is presented. The manufacturing apparatus comprises a tool support movable along multiple axes; a tool mounted on the tool support for performing a manufacturing operation on a workpiece; and an ancillary device releasably mounted on the tool support and used in conjunction with the tool, the ancillary device moveable along at least a first axis independent of the movement of the tool.Type: GrantFiled: May 27, 2013Date of Patent: December 6, 2016Assignee: THE BOEING COMPANYInventors: John A. Baumann, Herb Bommer, Kurt A. Burton, Mike P. Matlack
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Patent number: 9409253Abstract: In one aspect of the disclosure, an article for filling an opening in an object includes a plug having a body, a first flange, and a second flange. The plug has a trailing end. The first flange is in contact with the body and extends away from the body. The second flange is in contact with the first flange and extends away from the first flange and the body. The second flange is configured to deform toward the body upon installation of the plug into the opening. This deformation of the second flange rotationally and translationally secures the plug in the opening and consolidates the plug in the opening.Type: GrantFiled: January 25, 2016Date of Patent: August 9, 2016Assignee: The Boeing CompanyInventors: Mike P. Matlack, Amy M. Helvey, Randy A. Card
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Publication number: 20160136754Abstract: In one aspect of the disclosure, an article for filling an opening in an object includes a plug having a body, a first flange, and a second flange. The plug has a trailing end. The first flange is in contact with the body and extends away from the body. The second flange is in contact with the first flange and extends away from the first flange and the body. The second flange is configured to deform toward the body upon installation of the plug into the opening. This deformation of the second flange rotationally and translationally secures the plug in the opening and consolidates the plug in the opening.Type: ApplicationFiled: January 25, 2016Publication date: May 19, 2016Applicant: The Boeing CompanyInventors: Mike P. Matlack, Amy M. Helvey, Randy A. Card
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Publication number: 20160067817Abstract: One example of the present disclosure relates to a method of processing first and second workpieces. The method includes constraining the second workpiece; abutting first and second workpieces together to form a joint; applying first and second selectively adjustable forces against the first workpiece to bias the first workpiece against the second workpiece; friction stir welding the first and second workpieces along the joint; maintaining the forces equal to each other while friction stir welding; and automatically varying at least one of the forces responsive to thermal size variations of the first and second workpieces. An apparatus for carrying out this method is also provided.Type: ApplicationFiled: November 18, 2015Publication date: March 10, 2016Inventors: Mike P. MATLACK, Kurt A. BURTON, John A. BAUMANN
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Patent number: 9272362Abstract: In one aspect of the disclosure, an article for filling an opening in an object includes a plug having a body, a first flange, and a second flange. The plug has a trailing end. The first flange is in contact with the body and extends away from the body. The second flange is in contact with the first flange and extends away from the first flange and the body. The second flange is configured to deform toward the body upon installation of the plug into the opening. This deformation of the second flange rotationally and translationally secures the plug in the opening and consolidates the plug in the opening.Type: GrantFiled: April 30, 2015Date of Patent: March 1, 2016Assignee: The Boeing CompanyInventors: Mike P. Matlack, Amy M. Helvey, Randy A. Card
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Patent number: 9205533Abstract: One example of the present disclosure relates to a method of processing first and second workpieces. The method includes constraining the second workpiece; abutting first and second workpieces together to form a joint; applying first and second selectively adjustable forces against the first workpiece to bias the first workpiece against the second workpiece; friction stir welding the first and second workpieces along the joint; maintaining the forces equal to each other while friction stir welding; and automatically varying at least one of the forces responsive to thermal size variations of the first and second workpieces. An apparatus for carrying out this method is also provided.Type: GrantFiled: April 21, 2014Date of Patent: December 8, 2015Assignee: The Boeing CompanyInventors: Mike P. Matlack, Kurt A. Burton, John A. Baumann
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Publication number: 20150298297Abstract: One example of the present disclosure relates to a method of processing first and second workpieces. The method includes constraining the second workpiece; abutting first and second workpieces together to form a joint; applying first and second selectively adjustable forces against the first workpiece to bias the first workpiece against the second workpiece; friction stir welding the first and second workpieces along the joint; maintaining the forces equal to each other while friction stir welding; and automatically varying at least one of the forces responsive to thermal size variations of the first and second workpieces. An apparatus for carrying out this method is also provided.Type: ApplicationFiled: April 21, 2014Publication date: October 22, 2015Inventors: Mike P. Matlack, Kurt A. Burton, John A. Baumann
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Publication number: 20150231733Abstract: In one aspect of the disclosure, an article for filling an opening in an object includes a plug having a body, a first flange, and a second flange. The plug has a trailing end. The first flange is in contact with the body and extends away from the body. The second flange is in contact with the first flange and extends away from the first flange and the body. The second flange is configured to deform toward the body upon installation of the plug into the opening. This deformation of the second flange rotationally and translationally secures the plug in the opening and consolidates the plug in the opening.Type: ApplicationFiled: April 30, 2015Publication date: August 20, 2015Applicant: The Boeing CompanyInventors: Mike P. Matlack, Amy M. Helvey, Randy A. Card
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Patent number: 9056370Abstract: In one aspect of the disclosure, an article for filling an opening in an object includes a plug having a body, a first flange, and a second flange. The plug has a trailing end. The first flange is in contact with the body and extends away from the body. The second flange is in contact with the first flange and extends away from the first flange and the body. The second flange is configured to deform toward the body upon installation of the plug into the opening. This deformation of the second flange rotationally and translationally secures the plug in the opening and consolidates the plug in the opening.Type: GrantFiled: October 1, 2013Date of Patent: June 16, 2015Assignee: The Boeing CompanyInventors: Mike P. Matlack, Amy M. Helvey, Randy A. Card
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Patent number: 9022376Abstract: A reconfigurable clamping system is disclosed. An example clamping system for securing a workpiece comprises a retention assembly and an inflatable bladder. The retention assembly comprises a plurality of links, each pair of adjacent links having a pivotal connection to enable the retention assembly to be configured to the general shape of a workpiece, and each pair of adjacent links having a locking mechanism to selectively lock an angular relationship between the pair. The inflatable bladder is coupled between the retention assembly and the workpiece and is to apply a clamping force to the workpiece.Type: GrantFiled: July 1, 2013Date of Patent: May 5, 2015Assignee: The Boeing CompanyInventors: Mike P. Matlack, Kurt A. Burton, John A. Baumann
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Patent number: 8757468Abstract: A counter-rotating spindle includes a shoulder tool, a pin tool inserted in the shoulder tool, a first motor that is connected with the pin tool and rotates the pin tool, and a second motor that is connected with the shoulder tool and rotates the shoulder tool. The direction and the speed of the rotation for the pin tool may be selected independently from the speed and direction of rotation of the shoulder tool enabling optimization of the friction stir welding process. Counter-rotating the pin tool and the shoulder tool may improve the mixing abilities and efficiency of the pin tool and may prevent the galling effect between the pin tool and the shoulder tool. The counter-rotating spindle may be used, for example, for continuous path friction stir welding and spot welding of aluminum and its alloys, including cast alloys, as well as joining similar and dissimilar alloys.Type: GrantFiled: January 30, 2013Date of Patent: June 24, 2014Assignee: The Boeing CompanyInventors: Kurt A. Burton, Mike P. Matlack
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Patent number: 8662372Abstract: A spindle head for performing friction stir welding includes concentric spindle shafts driven by stacked, coaxial motors contained within a spindle housing. The coaxial arrangement of the motors results in a more compact package. Each of the motors is concentrically arranged around one of the spindles by directly connecting a rotor of the motor to a spindle shaft. The stators of the motors are mounted on the housing and are concentrically arranged around the concentric spindle shafts.Type: GrantFiled: February 13, 2013Date of Patent: March 4, 2014Assignee: The Boeing CompanyInventors: Kurt A. Burton, Mike P. Matlack, John Baumann, Herb Bommer
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Publication number: 20130292891Abstract: A reconfigurable clamping system is disclosed. An example clamping system for securing a workpiece comprises a retention assembly and an inflatable bladder. The retention assembly comprises a plurality of links, each pair of adjacent links having a pivotal connection to enable the retention assembly to be configured to the general shape of a workpiece, and each pair of adjacent links having a locking mechanism to selectively lock an angular relationship between the pair. The inflatable bladder is coupled between the retention assembly and the workpiece and is to apply a clamping force to the workpiece.Type: ApplicationFiled: July 1, 2013Publication date: November 7, 2013Inventors: Mike P. Matlack, Kurt A. Burton, John A. Baumann