Patents by Inventor Steven J. Burpo
Steven J. Burpo 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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Publication number: 20220212423Abstract: A drape forming apparatus includes a forming tool having a first forming surface and a second forming surface nonplanar with the first forming surface. A tray is spaced apart from the forming tool and is configured to pivot about a hinged end from a first position to a second position under an applied force such that a distal end moves away from the forming tool. A first side of the tray faces a first heat source when the tray is in the first position, and a second heat source is disposed at a second side of the tray. A device for use in forming the composite structure includes a standoff and the tray, and a heat source is secured to the second side of the tray. A method of forming a composite structure includes heating both sides of the composite material with the first and second heat sources.Type: ApplicationFiled: December 10, 2021Publication date: July 7, 2022Applicant: The Boeing CompanyInventors: David John Sundquist, Trevor Lee Howard, Steven J. Burpo, Kurtis Shuldberg Willden
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Patent number: 10814602Abstract: A composite structure includes a base structure, a core disposed on the base structure, the core having a non-uniform contour relative to the base structure, a layered cover material disposed on the base structure covering the core, the layered cover material conforming to the non-uniform contour of the core and having at least one overlay ply, each of the at least one overlay ply having at least one slit cut through fibers of the respective overlay ply, and at least one cover ply having a shape that spans the at least one slit, and being configured to transfer a load across the at least one slit.Type: GrantFiled: September 14, 2016Date of Patent: October 27, 2020Assignee: The Boeing CompanyInventors: David J. Sundquist, Steven J. Burpo, Trevor Howard
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Patent number: 10688697Abstract: A drape forming apparatus for use in forming a composite structure. The apparatus includes a forming tool including an upper forming surface and at least one side forming surface that extends from the upper forming surface. The forming tool receives at least one layer of composite material over the upper forming surface. The apparatus also includes a flange forming device including a tray coplanarly aligned with the upper forming surface when in a first operating position. The tray is configured to receive a flange portion of the at least one layer of composite material. A pressurized bladder extends over the forming tool and the tray. The pressurized bladder is configured to induce a first force against the tray such that the tray rotates about a pivot line, and such that the flange portion is withdrawn from the tray and draped over the at least one side forming surface.Type: GrantFiled: January 22, 2016Date of Patent: June 23, 2020Assignee: The Boeing CompanyInventors: David John Sundquist, Trevor Lee Howard, Eric Eldon Deck, Steven J. Burpo, Kurtis Shuldberg Willden
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Patent number: 10259176Abstract: A system includes a bladder configured to deform to at least partially surround a draping tool. The bladder has a pattern configured to distort as the bladder deforms. The system also includes an imaging device configured to generate image data of a sequence of images of the pattern of the bladder as the bladder deforms about the draping tool.Type: GrantFiled: August 3, 2016Date of Patent: April 16, 2019Assignee: THE BOEING COMPANYInventors: Eric E. Deck, Steven J. Burpo
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Patent number: 10239251Abstract: A drape forming apparatus for that includes a forming tool including an upper forming surface and a side forming surface extending from the upper forming surface. The forming tool receives a layer of composite material over the upper forming surface. The apparatus includes a flange forming device including an upper plate, a lower plate, and a receiving slot defined therebetween. The receiving slot receives a flange portion of the layer of composite material, and the flange forming device is translatable relative to the forming tool such that the flange portion of the layer of composite material is withdrawn from the receiving slot and draped over the side forming surface. The apparatus includes a pressurized bladder that extends over the forming tool and the upper plate. The pressurized bladder forces the flange portion against the side forming surface as the flange forming device translates relative to the forming tool.Type: GrantFiled: January 22, 2016Date of Patent: March 26, 2019Assignee: The Boeing CompanyInventors: Eric Eldon Deck, Steven J. Burpo, Allyson Antonio, David John Sundquist, Trevor Lee Howard, Zachary Benjamin Renwick
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Patent number: 10040222Abstract: A collapsible, coiled mandrel, for use in co-curing of a hollow carbon-epoxy structure such as a stringer in aircraft construction, is made of a coil having an outer coil shape resistant to external compression forces when used as a mandrel during lay-up and curing, and is collapsible when an end of the coil is pulled along its longitudinal axis so that it can be easily removed after curing and discarded.Type: GrantFiled: July 5, 2017Date of Patent: August 7, 2018Assignee: The Boeing CompanyInventors: Steven M. Gunther, Steven J. Burpo
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Publication number: 20180072432Abstract: A composite structure includes a base structure, a core disposed on the base structure, the core having a non-uniform contour relative to the base structure, a layered cover material disposed on the base structure covering the core, the layered cover material conforming to the non-uniform contour of the core and having at least one overlay ply, each of the at least one overlay ply having at least one slit cut through fibers of the respective overlay ply, and at least one cover ply having a shape that spans the at least one slit, and being configured to transfer a load across the at least one slit.Type: ApplicationFiled: September 14, 2016Publication date: March 15, 2018Inventors: David J. SUNDQUIST, Steven J. BURPO, Trevor HOWARD
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Publication number: 20180036967Abstract: A system includes a bladder configured to deform to at least partially surround a draping tool. The bladder has a pattern configured to distort as the bladder deforms. The system also includes an imaging device configured to generate image data of a sequence of images of the pattern of the bladder as the bladder deforms about the draping tool.Type: ApplicationFiled: August 3, 2016Publication date: February 8, 2018Inventors: Eric E. Deck, Steven J. Burpo
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Publication number: 20170297231Abstract: A collapsible, coiled mandrel, for use in co-curing of a hollow carbon-epoxy structure such as a stringer in aircraft construction, is made of a coil having an outer coil shape resistant to external compression forces when used as a mandrel during lay-up and curing, and is collapsible when an end of the coil is pulled along its longitudinal axis so that it can be easily removed after curing and discarded.Type: ApplicationFiled: July 5, 2017Publication date: October 19, 2017Applicant: The Boeing CompanyInventors: STEVEN M. GUNTHER, STEVEN J. BURPO
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Patent number: 9724891Abstract: A beaded composite panel is fabricated using composite plies. An opening is formed in each of plies, and each ply is laid up on a bead feature and drawn down over the bead feature in the area of the opening so as to widen the opening into a gap allowing the ply to conform to the contour of the bead feature. Patches are fabricated and placed on the plies overlying over the openings. The laid-up plies are compacted and cured.Type: GrantFiled: November 25, 2014Date of Patent: August 8, 2017Assignee: THE BOEING COMPANYInventors: Steven J. Burpo, Michael P. Renieri, Nicholas B. Segobiano, Neal A. Froeschner
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Patent number: 9724848Abstract: A collapsible, coiled mandrel, for use in co-curing of a hollow carbon-epoxy structure such as a stringer in aircraft construction, is made of a fiber stiffened with doping material that maintains an outer coil shape resistant to external compression forces when used as a mandrel during lay-up and curing, and is collapsible when an end of the fiber is pulled along its longitudinal axis so that it can be easily removed after curing and discarded. A method of fabricating a collapsible, coiled mandrel employs a mold with a shaped recess for forming a coil with a fiber wetted with a doping material fed in by an applicator, and rotating the applicator while backing it out to form the coil in the mold. In an alternative embodiment, a collapsible, coiled mandrel may be formed of a metal coil having a mandrel-shaped cross section and sleeved in a protective liner.Type: GrantFiled: July 3, 2014Date of Patent: August 8, 2017Assignee: THE BOEING COMPANYInventors: Steven M. Gunther, Steven J. Burpo
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Publication number: 20170210040Abstract: A drape forming apparatus for use in forming a composite structure is provided. The apparatus includes a forming tool including an upper forming surface and at least one side forming surface that extends from the upper forming surface. The forming tool is configured to receive at least one layer of composite material extending over the upper forming surface. The apparatus also includes a flange forming device including a tray coplanarly aligned with the upper forming surface when in a first operating position. The tray is configured to receive a flange portion of the at least one layer of composite material. A pressurized bladder extends over the forming tool and the tray. The pressurized bladder is configured to induce a first force against the tray such that the tray rotates about a pivot line, and such that the flange portion is withdrawn from the tray and draped over the at least one side forming surface.Type: ApplicationFiled: January 22, 2016Publication date: July 27, 2017Inventors: David John Sundquist, Trevor Lee Howard, Eric Eldon Deck, Steven J. Burpo, Kurtis Shuldberg Willden
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Publication number: 20170210054Abstract: A drape forming apparatus for use in forming a composite structure is provided. The apparatus includes a forming tool including an upper forming surface and a side forming surface extending from the upper forming surface. The forming tool receives a layer of composite material extending over the upper forming surface. The apparatus further includes a flange forming device including an upper plate, a lower plate, and a receiving slot defined therebetween. The receiving slot for receiving a flange portion of the layer of composite material, and wherein the flange forming device is translatable relative to the forming tool such that the flange portion of the layer of composite material is withdrawn from the receiving slot and draped over the side forming surface. The apparatus further includes a pressurized bladder configured to extend over the forming tool and the upper plate of the flange forming device.Type: ApplicationFiled: January 22, 2016Publication date: July 27, 2017Inventors: Eric Eldon Deck, Steven J. Burpo, Allyson Antonio, David John Sundquist, Trevor Lee Howard, Zachary Benjamin Renwick
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Patent number: 9545778Abstract: A mechanical pressure application system for applying a tailored pressure distribution to a plurality of structural components is provided. Each structural component has a first surface, and each first surface is configured to interface with the first surface of another of the structural components at a contact area. A base and at least one tooling block are configured to removably couple to the structural components. Each at least one tooling block includes a first surface configured to be positioned proximate at least one of the plurality of structural components. A second surface of each tooling block is configured to receive at least one forcing member. At least one biasing mechanism is configured to apply a predetermined load to the at least one forcing member, such that a force is transmitted from the at least one forcing member through the tooling block to a corresponding portion of the contact area.Type: GrantFiled: August 4, 2014Date of Patent: January 17, 2017Assignee: The Boeing CompanyInventors: Ryan Joseph Merriman, James R. Fox, Charles Richard Prebil, Steven J. Burpo
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Publication number: 20160031199Abstract: A mechanical pressure application system for applying a tailored pressure distribution to a plurality of structural components is provided. Each structural component has a first surface, and each first surface is configured to interface with the first surface of another of the structural components at a contact area. A base and at least one tooling block are configured to removably couple to the structural components. Each at least one tooling block includes a first surface configured to be positioned proximate at least one of the plurality of structural components. A second surface of each tooling block is configured to receive at least one forcing member. At least one biasing mechanism is configured to apply a predetermined load to the at least one forcing member, such that a force is transmitted from the at least one forcing member through the tooling block to a corresponding portion of the contact area.Type: ApplicationFiled: August 4, 2014Publication date: February 4, 2016Inventors: Ryan Joseph Merriman, James R. Fox, Charles Richard Prebil, Steven J. Burpo
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Publication number: 20160001467Abstract: A collapsible, coiled mandrel, for use in co-curing of a hollow carbon-epoxy structure such as a stringer in aircraft construction, is made of a fiber stiffened with doping material that maintains an outer coil shape resistant to external compression forces when used as a mandrel during lay-up and curing, and is collapsible when an end of the fiber is pulled along its longitudinal axis so that it can be easily removed after curing and discarded. A method of fabricating a collapsible, coiled mandrel employs a mold with a shaped recess for forming a coil with a fiber wetted with a doping material fed in by an applicator, and rotating the applicator while backing it out to form the coil in the mold. In an alternative embodiment, a collapsible, coiled mandrel may be formed of a metal coil having a mandrel-shaped cross section and sleeved in a protective liner.Type: ApplicationFiled: July 3, 2014Publication date: January 7, 2016Applicant: THE BOEING COMPANYInventors: STEVEN M. GUNTHER, STEVEN J. BURPO
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Publication number: 20150079338Abstract: A beaded composite panel is fabricated using composite plies. An opening is formed in each of plies, and each ply is laid up on a bead feature and drawn down over the bead feature in the area of the opening so as to widen the opening into a gap allowing the ply to conform to the contour of the bead feature. Patches are fabricated and placed on the plies overlying over the openings. The laid-up plies are compacted and cured.Type: ApplicationFiled: November 25, 2014Publication date: March 19, 2015Inventors: Steven J. Burpo, Michael P. Renieri, Nicholas B. Segobiano, Neal A. Froeschner
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Patent number: 8916253Abstract: A beaded composite panel is fabricated using composite plies. An opening is formed in each of plies, and each ply is laid up on a bead feature and drawn down over the bead feature in the area of the opening so as to widen the opening into a gap allowing the ply to conform to the contour of the bead feature. Patches are fabricated and placed on the plies overlying over the openings. The laid-up plies are compacted and cured.Type: GrantFiled: August 29, 2011Date of Patent: December 23, 2014Assignee: The Boeing CompanyInventors: Steven J. Burpo, Michael P. Renieri, Nicholas B. Segobiano, Neal A. Froeschner
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Patent number: 8583271Abstract: An apparatus may comprise a nondestructive evaluation system and a cutting system. The nondestructive evaluation system may be configured to inspect a processed portion of a structure. The nondestructive evaluation system may be configured to determine whether an inconsistency is present in the processed portion. The nondestructive evaluation system may also be configured to generate information about a location of the inconsistency. The cutting system may be configured to cut a number of parts out of the processed portion of the structure in which the inconsistency may be at least substantially excluded from the number of parts.Type: GrantFiled: March 16, 2009Date of Patent: November 12, 2013Assignee: The Boeing CompanyInventors: Roger W. Engelbart, Steven J. Burpo, Michael P. Renieri
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Publication number: 20110311778Abstract: A beaded composite panel is fabricated using composite plies. An opening is formed in each of plies, and each ply is laid up on a bead feature and drawn down over the bead feature in the area of the opening so as to widen the opening into a gap allowing the ply to conform to the contour of the bead feature. Patches are fabricated and placed on the plies overlying over the openings. The laid-up plies are compacted and cured.Type: ApplicationFiled: August 29, 2011Publication date: December 22, 2011Applicant: THE BOEING COMPANYInventors: Steven J. Burpo, Michael P. Renieri, Nicholas B. Segobiano, Neal A. Froeschner