Patents Assigned to Ebert Composites Corporation
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Patent number: 11400665Abstract: A system for sequential circumferential deposition of thermoplastic composite prepreg material to layer plies of prepreg tape, allowing the continuous processing of tubular shapes and rods, comprising a floating mandrel; a first heatable folding shoe configured to heat and wrap a first prepreg tape onto the floating mandrel; a first forming tube configured to heat and pultrude the first prepreg tape so as to form a first layer ply of prepreg tape on the floating mandrel; a second heatable folding shoe configured to heat and wrap a second prepreg tape onto the first layer ply of prepreg tape on the floating mandrel; a second forming tube configured to heat and pultrude the second prepreg tape so as to form a second layer ply of prepreg tape over the first layer ply of prepreg tape on the floating mandrel.Type: GrantFiled: July 15, 2020Date of Patent: August 2, 2022Assignee: Ebert Composites CorporationInventors: David W. Johnson, D. Michael Gordon
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Patent number: 10449737Abstract: A 3D thermoplastic pultrusion system and method based upon a 3D variable die system and including one or more sets of 3D thermoplastic forming machines to continuously produce thermoplastic composite pultrusions with at least one of varying cross-section geometry and constant surface contours, varying cross-section geometry and varying surface contours, and constant cross-section geometry and varying surface contours. The 3D thermoplastic pultrusion system and method including at least one of multiple pairs of shapeable and flexible bands and a rotating assembly that rotates the one or more sets of 3D thermoplastic forming machines to impart a twist to the thermoplastic composite.Type: GrantFiled: July 13, 2018Date of Patent: October 22, 2019Assignee: Ebert Composites CorporationInventors: David W. Johnson, Scott A. Garrett, Stephen G. Moyers
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Patent number: 10328641Abstract: A method of processing a thermoplastic composite tubular lineal comprising providing a pre-pregged thermoplastic composite around an elongated stationary mandrel; wrapping the pre-pregged thermoplastic composite with a release material; heating the stationary mandrel so that the pre-pregged thermoplastic composite melts and the release material contracts, exerting pressure on the pre-pregged material; cooling the pre-pregged material and release material so as to form a thermoplastic composite tubular lineal in its final configuration; pulling the thermoplastic composite tubular lineal downstream; and removing the release material from the thermoplastic composite tubular lineal.Type: GrantFiled: May 22, 2018Date of Patent: June 25, 2019Assignee: Ebert Composites CorporationInventors: David W. Johnson, Scott A. Garrett, Stephen G. Moyers
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Patent number: 10190424Abstract: A 3D thermoplastic pultrusion system, comprises one or more sets of 3D thermoplastic forming machines; a CNC control system controlling the one or more sets of 3D thermoplastic forming machines to form a heated prepreg thermoplastic composite material into a 3D thermoplastic composite pultrusion, the one or more sets of 3D thermoplastic forming machines include a plurality of motion control CNC rotational motors and CNC actuators operatively coupled to the motion control CNC rotational motors, a flexible chilled band shapeable by the CNC actuators to form the heated prepreg thermoplastic composite material into the thermoplastic composite pultrusion, and bearings that the motion control CNC rotational motors pivot the actuators about and hold the actuators in position during a consolidation process.Type: GrantFiled: May 2, 2018Date of Patent: January 29, 2019Assignee: Ebert Composites CorporationInventors: David W. Johnson, Scott A. Garrett, Stephen G. Moyers
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Patent number: 10124546Abstract: A 3D thermoplastic pultrusion system and method based upon a 3D variable die system and including one or more sets of 3D thermoplastic forming machines to continuously produce thermoplastic composite pultrusions with at least one of varying cross-section geometry and constant surface contours, varying cross-section geometry and varying surface contours, and constant cross-section geometry and varying surface contours. The 3D thermoplastic pultrusion system and method including at least one of one or more pairs of shapeable and flexible dual-temperature bands and a rotating assembly that rotates the one or more sets of 3D thermoplastic forming machines to impart a twist to the thermoplastic composite.Type: GrantFiled: September 8, 2017Date of Patent: November 13, 2018Assignee: Ebert Composites CorporationInventors: David W. Johnson, Scott A. Garrett, Stephen G. Moyers
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Patent number: 9963978Abstract: A 3D thermoplastic pultrusion system, comprises one or more sets of 3D thermoplastic forming machines; a CNC control system controlling the one or more sets of 3D thermoplastic forming machines to form a heated prepreg thermoplastic composite material into a 3D thermoplastic composite pultrusion, the one or more sets of 3D thermoplastic forming machines include a plurality of motion control CNC rotational motors and CNC actuators operatively coupled to the motion control CNC rotational motors, a flexible chilled band shapeable by the CNC actuators to form the heated prepreg thermoplastic composite material into the thermoplastic composite pultrusion, and bearings that the motion control CNC rotational motors pivot the actuators about and hold the actuators in position during a consolidation process.Type: GrantFiled: December 14, 2015Date of Patent: May 8, 2018Assignee: Ebert Composites CorporationInventors: David W. Johnson, Scott A. Garrett, Stephen G. Moyers
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Patent number: 9764520Abstract: A 3D thermoplastic pultrusion system and method based upon a 3D variable die system and including one or more sets of 3D thermoplastic forming machines to continuously produce thermoplastic composite pultrusions with at least one of varying cross-section geometry and constant surface contours, varying cross-section geometry and varying surface contours, and constant cross-section geometry and varying surface contours.Type: GrantFiled: February 27, 2017Date of Patent: September 19, 2017Assignee: Ebert Composites CorporationInventors: David W. Johnson, Scott A. Garrett, Stephen G. Moyers
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Patent number: 9735466Abstract: A radome for housing a radar system comprises a plurality of interconnected curved radome thermoplastic composite material panels, each curved radome thermoplastic composite material panel having a plurality of interconnecting edges, a foam core, an inner skin, an outer skin, and a plurality of three-dimensional fiber bundles tying the inner skin and the outer skin to each other through the foam core, inhibiting delamination. The radome includes a hydrophobic exterior surface that is self-cleaning and requires zero maintenance for 25 years.Type: GrantFiled: July 16, 2014Date of Patent: August 15, 2017Assignee: Ebert Composites CorporationInventors: David W. Johnson, Scott A. Garrett, Stephen G. Moyers
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Patent number: 9724881Abstract: A 3D thermoplastic pultrusion system and method based upon a 3D variable die system and including one or more sets of 3D thermoplastic forming machines to continuously produce thermoplastic composite pultrusions with at least one of varying cross-section geometry and constant surface contours, varying cross-section geometry and varying surface contours, and constant cross-section geometry and varying surface contours.Type: GrantFiled: February 27, 2017Date of Patent: August 8, 2017Assignee: EBERT COMPOSITES CORPORATIONInventors: David W. Johnson, Scott A. Garrett, Stephen G. Moyers
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Patent number: 9656781Abstract: A 3D Z-axis fiber composite pallet, comprising a Z-axis reinforced sandwich panel including a bottom surface with a plurality of bolted-on and/or structurally bonded blocks that accommodate forks of a forklift there between, and a tough coating applied to surfaces of the 3D Z-axis fiber composite pallet.Type: GrantFiled: March 31, 2016Date of Patent: May 23, 2017Assignee: Ebert Composites CorporationInventors: David W. Johnson, Scott A. Garrett, Stephen G. Moyers
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Patent number: 9616623Abstract: A 3D thermoplastic pultrusion system and method based upon a 3D variable die system and including one or more sets of 3D thermoplastic forming machines to continuously produce thermoplastic composite pultrusions with at least one of varying cross-section geometry and constant surface contours, varying cross-section geometry and varying surface contours, and constant cross-section geometry and varying surface contours.Type: GrantFiled: September 24, 2015Date of Patent: April 11, 2017Assignee: Ebert Composites CorporationInventors: David W. Johnson, Scott A. Garrett, Stephen G. Moyers
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Patent number: 9610737Abstract: A 3D thermoplastic pultrusion system and method based upon a 3D variable die system and including one or more sets of 3D thermoplastic forming machines to continuously produce thermoplastic composite pultrusions with at least one of varying cross-section geometry and constant surface contours, varying cross-section geometry and varying surface contours, and constant cross-section geometry and varying surface contours.Type: GrantFiled: January 28, 2016Date of Patent: April 4, 2017Assignee: Ebert Composites CorporationInventors: David W. Johnson, Scott A. Garrett, Stephen G. Moyers
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Patent number: 9062662Abstract: A hybrid wind turbine tower support structure that combines pultruded fiber glass composites lineals with reinforced concrete, effectively creating a low cost structure for holding large, laterally-forced-thrusts from wind turbine rotor blades. The structure is designed to be lower in installed costs then its counterpart steel support structure, yet be capable of withstanding very large thrust loads, deflecting-under-load less than or equal to, but no more, under extreme wind loading, than its counterpart, steel support structure.Type: GrantFiled: March 26, 2014Date of Patent: June 23, 2015Assignee: Ebert Composites CorporationInventors: David W. Johnson, H. Peter Fay
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Patent number: 8747098Abstract: A thermoplastic pultrusion die system for pultruding a thermoplastic composite includes a first pultrusion die member with a curved, concave top surface; a second pultrusion die member with a curved, convex bottom surface; a curved die cavity gap formed between the a curved, concave top surface of the first pultrusion die member and the curved, convex bottom surface of the second pultrusion die member; a die cavity gap adjustment mechanism that imparts movement to at least one of the first pultrusion die member and the second pultrusion die member to vary the die cavity gap from closed to a specified location to open at a specified location; a pultrusion gripper mechanism having one or more grippers in series, and a computer numerical control (CNC) computer system controlling the die cavity gap adjustment mechanism.Type: GrantFiled: October 9, 2013Date of Patent: June 10, 2014Assignee: Ebert Composites CorporationInventors: David W. Johnson, Scott A. Garrett, Stephen G. Moyers
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Patent number: 8684722Abstract: A thermoplastic pultrusion die system for pultruding a thermoplastic composite includes a first pultrusion die member; a second pultrusion die member; a die cavity gap formed between the first pultrusion die member and the second pultrusion die member; and a die cavity gap adjustment mechanism that imparts movement to at least one of the first pultrusion die member and the second pultrusion die member to vary the die cavity gap within a very tight die cavity gap tolerance.Type: GrantFiled: January 10, 2013Date of Patent: April 1, 2014Assignee: Ebert Composites CorporationInventors: David W. Johnson, Scott A. Garrett, Stephen G. Moyers
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Patent number: 8353694Abstract: A thermoplastic pultrusion die system for pultruding a thermoplastic composite includes a first pultrusion die member; a second pultrusion die member; a die cavity gap formed between the first pultrusion die member and the second pultrusion die member; and a die cavity gap adjustment mechanism that imparts movement to at least one of the first pultrusion die member and the second pultrusion die member to vary the die cavity gap within a very tight die cavity gap tolerance.Type: GrantFiled: February 28, 2012Date of Patent: January 15, 2013Assignee: Ebert Composites CorporationInventors: David W. Johnson, Scott A. Garrett, Stephen G. Moyers
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Patent number: 8302363Abstract: An interlocking support structure has an array of rectangular cells arranged in at least one layer, each cell having four sides, opposite ends, and eight corners, and sharing common sides and corners with any adjacent cells. The cells are formed by sets of spaced, parallel elongate members extending in x, y and z directions, with the x, y and z members interlocked with one another at the corners of the cells to form interlocking corner joints. Each structural member is hollow at least in the vicinity of each corner joint with which it intersects, and communicates with the other structural members at the respective corner joints. A plug of hardened, initially flowable material fills the hollow interior of the interlocking structural members at least at the corner joints and adheres to the internal surfaces of the members at the corner joints to secure the members together at each corner in the rectangular array.Type: GrantFiled: May 12, 2010Date of Patent: November 6, 2012Assignee: Ebert Composites CorporationInventor: David W. Johnson
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Patent number: 8272188Abstract: A composite laminate structure includes a first skin; a second skin; and a plurality of distinct groupings of Z-axis fibers that extend from the first skin to the second skin, wherein the Z-axis fibers include opposite ends respectively terminating at and integrated into the first skin and the second skin.Type: GrantFiled: December 7, 2010Date of Patent: September 25, 2012Assignee: Ebert Composites CorporationInventors: David W. Johnson, Scott A. Garrett, Stephen G. Moyers, James M. Hook
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Patent number: D762939Type: GrantFiled: May 15, 2015Date of Patent: August 2, 2016Assignee: Ebert Composite CorporationInventors: David W. Johnson, Scott A. Garrett, Stephen G. Moyers
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Patent number: D781023Type: GrantFiled: April 9, 2015Date of Patent: March 7, 2017Assignee: Ebert Composites CorporationInventors: David W. Johnson, Scott A. Garrett, Stephen G. Moyers