Patents Assigned to Hexcel Corporation
  • Patent number: 11161967
    Abstract: A powder composition suitable for use in selective laser sintering for printing an object. The powder composition includes a first fraction including a plurality of polyaryletherketone (PAEK) particles having a mean diameter less than 30 microns, a second fraction having a plurality of polyaryletherketone (PAEK) particles having a mean diameter greater than 30 microns, and a third fraction having a plurality of carbon fibers. The first fraction and the second fraction are formed by an air classification separation performed on a pulverized powder. After the separation, the first fraction, the second fraction, and the third fraction are blended in a high intensity mixer. The powder composition when used in selective laser sinter results in parts with increased tensile strength and reduced surface roughness, among other improvements, as compared to similar powders omitting the first fraction. The PAEK may include polyetherketoneketone (PEKK).
    Type: Grant
    Filed: January 31, 2020
    Date of Patent: November 2, 2021
    Assignee: Hexcel Corporation
    Inventors: Whitney Kline, Lawrence Varholak
  • Patent number: 11123899
    Abstract: Method for seaming a multi-sectional composite tooling for use in molding large composite structures. The tooling includes at least two tooling sections that are made from quasi-isotropic sheet molding compound. The two tooling sections are seamed together with a scarf plug at the tooling surface. The scarf plug is composed of specially oriented layers of consolidated quasi-isotropic sheet molding compound. The scarf plug is made from the same type of quasi-isotropic sheet molding compound that is used to make the tooling sections.
    Type: Grant
    Filed: April 17, 2019
    Date of Patent: September 21, 2021
    Assignee: HEXCEL CORPORATION
    Inventors: Mark Gerdisch, Richard Callis, Adam Senta
  • Patent number: 11090838
    Abstract: A powder composition suitable for use in laser sintering for printing a three-dimensional object. The powder composition includes a polyaryletherketone (PAEK) powder having a plurality of particles. The plurality of particles having a mean diameter of D50. The composition includes a plurality of carbon fibers having a mean length L50. L50 is greater than D50. The particles are substantially non-spherical. A portion of the carbon fiber is embedded into the particle via high intensity mixing.
    Type: Grant
    Filed: April 21, 2020
    Date of Patent: August 17, 2021
    Assignee: Hexcel Corporation
    Inventors: Scott DeFelice, Anthony DeCarmine
  • Publication number: 20210142774
    Abstract: Acoustic honeycomb structures that include cells in which a friction-locking insertion process is used to locate acoustic barriers within honeycomb cells to provide multiple degree of freedom (MDOF) acoustic liners having a variety of acoustic resonator depths. Solid polymer films are formed into acoustic barrier caps. The acoustic barrier caps are friction-locked and bonded to cell walls at one or more cell depths to form acoustically reflective hard walls that form effective bottom ends for acoustic resonators.
    Type: Application
    Filed: November 12, 2019
    Publication date: May 13, 2021
    Applicant: Hexcel Corporation
    Inventors: Merid Minasse HAILE, Lisa Diane BOWEN, Clark Russell SMITH
  • Publication number: 20210138689
    Abstract: A powder composition suitable for laser sintering for printing a three-dimensional object obtained by pre-heating a raw PEKK to evaporate a liquid solvent in the raw PEKK and the grinding the raw PEKK to form a PEKK powder, the powder composition having a first fraction comprising a polyetherketoneketone (PEKK) powder having a plurality of particles, the plurality of particles having a mean diameter D50 in the range of 30 ?m to 150 ?m. The plurality of particles of the first fraction are substantially non-spherical.
    Type: Application
    Filed: January 18, 2021
    Publication date: May 13, 2021
    Applicant: Hexcel Corporation
    Inventors: Scott DeFelice, Anthony DeCarmine
  • Publication number: 20210122891
    Abstract: Pre-impregnated composite material (prepreg) that can be cured/molded to form aerospace composite parts. The prepreg includes carbon reinforcing fibers and an uncured resin matrix. The resin matrix includes an epoxy resin component, polyethersulfone as a toughening agent, a thermoplastic particle component, a nanoparticle component and a curing agent.
    Type: Application
    Filed: October 23, 2019
    Publication date: April 29, 2021
    Applicant: Hexcel Corporation
    Inventors: Yan ZHU, Gordon T. EMMERSON
  • Patent number: 10947354
    Abstract: Composite honeycomb that may be contoured to form composite honeycomb structures, which have tight radii of curvatures and/or compound curvatures, and which are suitable for use in high temperature environments. The method for making the composite honeycomb involves using high temperature prepreg to make a flexible composite honeycomb that is formed into a composite honeycomb precursor. A high temperature coating resin is applied to the composite honeycomb precursor to form the high temperature composite honeycomb.
    Type: Grant
    Filed: July 22, 2019
    Date of Patent: March 16, 2021
    Assignee: HEXCEL CORPORATION
    Inventors: Robert Charles Loesch, Merid Minasse Haile, Earl Frederick Ayle, Clark Russell Smith
  • Publication number: 20210054538
    Abstract: A method for making carbon fiber in which the tensile strength of carbon fiber is increased without dehumidifying the ambient air that enters every oxidation oven in a multiple oxidation oven system. A positive effect on tensile strength is provided when ambient air entering only the first oven in a series of oxidation ovens is dehumidified. In addition, the ambient air entering the last oven is not dehumidified when one or more of the preceding oxidation ovens is operated with dehumidified air.
    Type: Application
    Filed: August 21, 2019
    Publication date: February 25, 2021
    Applicant: Hexcel Corporation
    Inventors: Peter Andrew FERRIN, Devon Cadwaladar Todd THOMAS
  • Patent number: 10926432
    Abstract: A method for preparing a PEKK powder for use in SLS includes the steps of: providing a raw, non-powder PEKK material; heat treating the raw PEKK to evaporate at least substantially all of a liquid solvent in the raw PEKK, causing at least substantially all of the raw PEKK to be in the form of irregularly-shaped particles; cooling the raw PEKK; and grinding the raw PEKK to form a PEKK powder.
    Type: Grant
    Filed: January 16, 2018
    Date of Patent: February 23, 2021
    Assignee: Hexcel Corporation
    Inventors: Scott DeFelice, Anthony DeCarmine
  • Patent number: 10894868
    Abstract: Provided is composite carbon fibers in which polymers having an amino containing group are covalently bonded to the surface of the carbon fiber. Aspects are also directed to processes for preparing the composite carbon fibers. Additional aspects are directed to reinforced composites comprising a resin matrix and the composite carbon fibers, and to processes of making such reinforced composites.
    Type: Grant
    Filed: December 21, 2017
    Date of Patent: January 19, 2021
    Assignee: Hexcel Corporation
    Inventor: Michael E. Yurchenko
  • Patent number: 10875250
    Abstract: A method of analytically determining a laser power for laser sintering includes choosing a batch of powder material for building a plurality of test rods; selecting a range of laser power for building the test rods; determining a plurality of power increments within the selected range to define a plurality of laser power settings; programming a laser sintering machine to build at least one test rod at each laser power setting; constructing the test rods; wherein the optimal power is at least one watt below a lowest laser power setting associated with the formation of voids; identifying the laser power setting used to construct a respective test rod without formation of voids in the surface as an optimal laser power; and configuring the selective laser sintering machine with the optimal laser power when conducting a laser sintering process using the chosen batch of powder material.
    Type: Grant
    Filed: January 16, 2018
    Date of Patent: December 29, 2020
    Assignee: Hexcel Corporation
    Inventors: Scott DeFelice, Anthony DeCarmine
  • Patent number: 10870130
    Abstract: A process for preparing a feedstock having polyaryletherketone particles for using in selective laser sintering. The process includes the steps of determining a particle size distribution of the polyaryletherketone particles in the feedstock based on a number of particles corresponding to each of a plurality of particle size ranges to obtain a particle size distribution determination. The process further includes the step of reducing the number of particles in the feedstock corresponding to one or more size ranges having a depressed melting temperature relative to the average melting temperature of the polyaryletherketone particles in the feedstock based on the particle size distribution determination.
    Type: Grant
    Filed: June 16, 2015
    Date of Patent: December 22, 2020
    Assignee: Hexcel Corporation
    Inventors: Scott DeFelice, Anthony DeCarmine
  • Patent number: 10787997
    Abstract: A semipreg that can be cured/molded to form aerospace composite parts including rocket booster casings. The semipreg includes a fibrous layer and a resin layer located on one side of the fibrous layer. The resin layer includes an epoxy component that is a combination of a hydrocarbon epoxy novolac resin and a trifunctional epoxy resin and optionally a tetrafunctional epoxy resin. The resin matrix includes polyethersulfone as a toughening agent and a thermoplastic particle component.
    Type: Grant
    Filed: October 3, 2019
    Date of Patent: September 29, 2020
    Assignee: HEXCEL CORPORATION
    Inventors: Kathlyn Lizette Baron, Gordon Emmerson, Yen-Seine Wang
  • Patent number: 10766197
    Abstract: A method of producing an object from a polymer powder using a laser sintering system, whereby the laser sintering system introduces heat energy to solidify select points of a layer of polymer powder according to build data of the object and adjusts the heat energy according to solidification of select points of other layers.
    Type: Grant
    Filed: March 27, 2017
    Date of Patent: September 8, 2020
    Assignee: Hexcel Corporation
    Inventors: Scott DeFelice, Anthony DeCarmine
  • Publication number: 20200255254
    Abstract: There is provide a process for unwinding material from a spool (2) wherein the angle (?) of take off at the first contact point (4) for the unwind is always in the range 0±20°, and wherein the first contact point (4) for the unwind is no more than 600 mm from the axis (3) of rotation of the spool (2). There is also provided an apparatus for the unwinding of material from a spool (2) comprising an axis (3) upon which a spool (2) may be rotatably mounted and a static first contact point (4) for the unwound material positioned no more than 600 mm from the centre of the axis (3), wherein the angle (?) of take off at the first contact point (4) for the unwind is always in the range 0±20°.
    Type: Application
    Filed: October 18, 2018
    Publication date: August 13, 2020
    Applicants: HEXCEL COMPOSITES LIMITED, HEXCEL CORPORATION
    Inventors: John ELLIS, Anthony LOCCISANO
  • Patent number: 10731014
    Abstract: Pre-impregnated composite material (prepreg) that can be cured/molded to form aerospace composite parts. The prepreg includes carbon reinforcing fibers and an uncured resin matrix. The resin matrix includes an epoxy component, polyethersulfone as a toughening agent, and a curing agent. The resin matrix is also composed of a thermoplastic particle component that includes hybrid polyamide particles wherein each hybrid particle contains a mixture of amorphous and semi-crystalline polyamide.
    Type: Grant
    Filed: July 3, 2019
    Date of Patent: August 4, 2020
    Assignee: HEXCEL CORPORATION
    Inventor: Yen-Seine Wang
  • Patent number: 10675684
    Abstract: A system for inspecting a part while said part is produced by additive manufacturing, includes an additive manufacturing apparatus having a build tray, the apparatus being configured to fabricate the part layer-by-layer on the tray; an automated tool holder carrying a tool configured to deposit, add or weld layer-upon-layer of material; the tool holder and tray are configured to move relative to one another along a defined path; and an inspection device attached to the tool holder and configured to scan a layer of material in situ. The tool holder alternately arranges the tool and inspection device in a working position so that the tool holder fixes the tool in the working position for depositing, adding, or welding the layer of material and thereafter the tool holder switches said tool with the inspection device into the working position for scanning and detecting defects in the layer of material.
    Type: Grant
    Filed: April 25, 2017
    Date of Patent: June 9, 2020
    Assignee: Hexcel Corporation
    Inventors: Scott DeFelice, Anthony DeCarmine
  • Publication number: 20200165417
    Abstract: A powder composition suitable for use in selective laser sintering for printing an object. The powder composition includes a first fraction including a plurality of polyaryletherketone (PAEK) particles having a mean diameter less than 30 microns, a second fraction having a plurality of polyaryletherketone (PAEK) particles having a mean diameter greater than 30 microns, and a third fraction having a plurality of carbon fibers. The first fraction and the second fraction are formed by an air classification separation performed on a pulverized powder. After the separation, the first fraction, the second fraction, and the third fraction are blended in a high intensity mixer. The powder composition when used in selective laser sinter results in parts with increased tensile strength and reduced surface roughness, among other improvements, as compared to similar powders omitting the first fraction. The PAEK may include polyetherketoneketone (PEKK).
    Type: Application
    Filed: January 31, 2020
    Publication date: May 28, 2020
    Applicant: Hexcel Corporation
    Inventors: Whitney Kline, Lawrence Varholak
  • Patent number: 10661479
    Abstract: A powder composition suitable for use in laser sintering for printing a three-dimensional object. The powder composition includes a polyaryletherketone (PAEK) powder having a plurality of particles. The plurality of particles having a mean diameter of D50. The composition includes a plurality of carbon fibers having a mean length L50. L50 is greater than D50. The particles are substantially non-spherical. A portion of the carbon fiber is embedded into the particle via high intensity mixing.
    Type: Grant
    Filed: January 16, 2018
    Date of Patent: May 26, 2020
    Assignee: Hexcel Corporation
    Inventors: Scott DeFelice, Anthony DeCarmine
  • Patent number: 10626799
    Abstract: Acoustic structures in which acoustic septa are located in the cells of a honeycomb for reducing the noise generated from a source. The honeycomb used to form the acoustic structure has walls that contain convex and concave contours which make the honeycomb flexible. The acoustic septa are formed by inserting planar acoustic inserts into the honeycomb cells to form a septum cap which is friction-locked within the cell and then permanently bonded in place. The planar acoustic septum is configured to match the unique shape of the cell contours to provide desired friction-locking when inserted into the cells and desired acoustic properties after being permanently bonded in place.
    Type: Grant
    Filed: July 19, 2017
    Date of Patent: April 21, 2020
    Assignee: HEXCEL CORPORATION
    Inventors: Lisa D. Bowen, Jessica Miller