Patents Examined by Matthew J Daniels
  • Patent number: 12030267
    Abstract: A curing mold for manufacturing a turbomachine part made of composite material from a preform produced by draping pre-impregnated materials includes: a first body and a second body designed to be attached to each other and jointly defining a fixed air gap for receiving the preform and itself including a molding part of complementary shape with the part to be manufactured and intended to receive a portion to be molded of the preform, and at least one additional part located in a peripheral space of the air gap and intended to receive an additional portion forming an edge of the preform; a heating member designed to heat the preform in the air gap to a first temperature; at least one inflatable bladder housed in the first or second body, facing an additional part of the air gap; a member for injecting a pressurized fluid inside the bladder(s).
    Type: Grant
    Filed: December 10, 2019
    Date of Patent: July 9, 2024
    Assignee: SAFRAN
    Inventors: Jérôme Olhagaray, Thierry Patrick Chauvin, Kris Hoes, Michel Wlasow Wlasowski
  • Patent number: 12023829
    Abstract: Devices and methods for producing a T-shaped semifinished product from a multiply non-crimp fabric with reinforcing fibers for a composite material. The product has a web and a flange. The device includes a web forming tool, with which a web portion of the non-crimp fabric is clamped in place, a forming tool, with which plies of a flange portion of the non-crimp fabric are split into two parts, a depositing device, with which a tube body is deposited on the flange portion formed into the flange, a holding tool, with which a clearance between the holding tool and the flange is formed, and a filling device, with which the tube body is filled with a gas such that the tube body fills the clearance and firmly holds the flange portion formed into the flange, and alternatively, a magnetic force can be generated between a sheet and the web forming tool.
    Type: Grant
    Filed: December 21, 2021
    Date of Patent: July 2, 2024
    Assignee: Airbus Operations GmbH
    Inventors: Olaf Rocker, Torben Jacob, Carsten Barlag, Alexander Gillessen, Thore Sdunnus
  • Patent number: 12011885
    Abstract: A thermoforming method includes forming a skin comprising a plurality of plies thermoplastic resin and fiber, securing an edge of the skin to a mandrel, heating, via a heating element, the skin to a forming temperature, moving a thermoforming apparatus with respect to the mandrel, rolling at least one roller of the thermoforming apparatus along the skin in a direction away from the clamped edge of the skin in response to the thermoforming apparatus moving with respect to the mandrel, and in response to the at least one roller of the thermoforming apparatus rolling along the skin, compressing the skin between the at least one roller and the mandrel, consolidating the plurality of plies of material, and bending the skin to conform to a shape of the mandrel. The consolidated and formed skin is then cooled and removed from the mandrel.
    Type: Grant
    Filed: November 15, 2022
    Date of Patent: June 18, 2024
    Assignee: ROHR, INC.
    Inventor: Stephen Harold Ward
  • Patent number: 11999118
    Abstract: A belt calender for manufacturing preimpregnated composites includes a first roller, which is rotatable around its longitudinal axis, a first belt running at least partly around the first roller; and a second belt running in between the first roller and the first belt. The first belt and the second belt guide a feed of material between them. The belt calender includes auxiliary rollers which are rotatable around their longitudinal axes, and are arranged substantially parallel to the first roller around at least a part of a circumference thereof. The first and second belt run in between two adjacent ones of the plurality of auxiliary rollers, thereby defining a meandering path for the feed of material. A method for manufacturing preimpregnated composites by using such a belt calender.
    Type: Grant
    Filed: January 30, 2020
    Date of Patent: June 4, 2024
    Assignee: KLIEVERIK HELI B.V.
    Inventors: Arnold August Petronella Marie D'Hondt, Johan Schenke
  • Patent number: 11993032
    Abstract: A mould for manufacturing a turbomachine fan casing made of a composite material with fibrous reinforcement that is densified by a matrix, includes an impregnation mandrel around which a fibrous preform is to be wound and angular counter-mould sectors assembled around the external contour of the impregnation mandrel, which are intended to close the mould. The impregnation mandrel includes a main body with an annular shape, and an annular barrel which is arranged around the main body and around which the fibrous preform is to be wound, the barrel and the angular sectors defining a moulding cavity intended to receive the fibrous preform. The main body and the angular sectors are made of a first material having a first thermal expansion coefficient, the barrel being made of a second material that has a second thermal expansion coefficient, the second thermal expansion coefficient being greater than the first thermal expansion coefficient.
    Type: Grant
    Filed: September 6, 2021
    Date of Patent: May 28, 2024
    Assignee: SAFRAN AIRCRAFT ENGINES
    Inventors: Maxime Marie Désiré Blaise, Hubert Jean Marie Fabre
  • Patent number: 11993388
    Abstract: A method may comprise: laying up a first plurality of plies of material comprising thermoplastic resin and fiber to form an inner skin preform, the inner skin preform being a continuous sheet including alternating peaks and valleys; laying up a second plurality of plies of material comprising thermoplastic resin and fiber to form an outer skin preform; and joining the inner skin preform to the outer skin preform.
    Type: Grant
    Filed: September 2, 2021
    Date of Patent: May 28, 2024
    Assignee: ROHR, INC.
    Inventors: Jennifer Davis, Nathaniel M. Gray
  • Patent number: 11993008
    Abstract: A method for forming at least one three-dimensional article through successive fusion of parts of a powder bed on a support structure, the method comprising the steps of: providing at least one model of the three-dimensional article, lowering the support structure a predetermined distance and rotating the support structure a predetermined angle in a first direction before applying a first powder layer covering the lowered and rotated support structure, rotating the support structure the predetermined angle in a second direction opposite to the first direction before directing the at least one first energy beam from the at least one first energy beam source at selected locations of the first powder layer, the at least one first energy beam source causing the first powder layer on the stationary support structure which is stationary to fuse in the selected locations according to the model to form first portions of the three-dimensional article.
    Type: Grant
    Filed: October 25, 2021
    Date of Patent: May 28, 2024
    Assignee: ARCAM AB
    Inventor: Calle Hellestam
  • Patent number: 11992994
    Abstract: A manufacturing system (1) for manufacturing shaped laminates including: forming tools (2.1, 2.2) extending along a longitudinal direction X, located parallel to one another and configured to receive a laminate (4) between the forming tools; a shaping tool (3) extending along the longitudinal direction X and along a transversal direction Z, and configured to receive the laminate (4) on an external surface of the shaping tool, wherein the forming tools (2.1, 2.2) or the shaping tool (3) are movable in the longitudinal direction X and in the transversal direction Z, relative to the at least one of the shaping tool (3) and the two forming tools (2.1, 2.2).
    Type: Grant
    Filed: April 22, 2022
    Date of Patent: May 28, 2024
    Assignee: AIRBUS OPERATIONS, S.L.U.
    Inventors: Diego García Martín, Raúl Burgos Gallego, Jorge Juan Galiana Blanco, Nuria Rodrigo Caballero, Aquilino García García, Augusto Pérez Pastor, Julián Martin Isabel, Fernando Muñoz Ajenjo
  • Patent number: 11981093
    Abstract: A method of forming a composite vehicle components (e.g. walls, floor, roof) having interleaved foam core members and pre-pultruded reinforcing pillars by pultruding the cores and pillars into a vehicle component (e.g. bus sidewall formed as integral component front to rear) and cutting apertures therein for insertion of vehicle accessories (e.g. windows). Also, vehicle components can be formed having interlocking profiled edges where a first component is inserted into a second component, and rotated to bring the two components into locking engagement. A plurality of components can be formed with the same geometry, and oriented 180 degrees offset from each other to bring their profiled edges adjacent to each other.
    Type: Grant
    Filed: October 13, 2021
    Date of Patent: May 14, 2024
    Assignee: TPI Composites, Inc.
    Inventors: Ahsan Uddin, John Perraut
  • Patent number: 11980307
    Abstract: A serving tray comprised of at least one synthetic material and an insert which provides a non-slip top surface of the serving tray. The textured relief is preferably made of thermoplastic polyurethane (TPU) which allows a glass or other item to be placed on the serving tray without the item sliding or slipping while the tray is in motion. As the tray is being fabricated, the TPU is mechanically bonded with the top surface of the tray while a textured relief is simultaneously defined into the top surface. The textured relief provides adequate frictional force to an item being placed on the tray so as to substantially prevent its lateral movement. The tray also includes an inner support structure disposed on its inner surface. The inner support structure provides an upward facing edge which allows a plurality of trays to be easily and efficiently stacked or nested on one another.
    Type: Grant
    Filed: July 9, 2021
    Date of Patent: May 14, 2024
    Assignee: Cambro Manufacturing Company
    Inventor: Jorge Baez
  • Patent number: 11981067
    Abstract: A multi-cavity mould (1) for a thermoforming machine used in the process of high-volume, continuous thermoforming of a plurality of thin-gauge plastic products (2) from a preheated thin-gauge thermoplastic sheet (3) comprising an upper tool (11) and a lower tool (12) arranged in a cooperating manner; the lower tool (12) comprising a plurality of cavities (8) in which cavity moulds (8) are placed and a plurality of base plates (91) from which a plurality of supporting blocks (92) extend perpendicularly over a predetermined total height (a), situated between adjacent cavities (8), each of said supporting block (92) has a stepped profile comprising three substantially rectangular shaped zones (92a, 92b, 92c) and a fourth substantially isosceles trapezoid shaped zone (92d) in a vertical cross section, having a common symmetry axis.
    Type: Grant
    Filed: April 24, 2019
    Date of Patent: May 14, 2024
    Inventor: Ionel-Dan Dragulinescu
  • Patent number: 11981415
    Abstract: An improved composite stiffener and methods and tooling used to form the same. The stiffener includes one or more base flanges, a composite rod extending in an axial direction, a bulb cap surrounding the composite rod, and an upright web extending from the one or more base flanges to the base cap. The upright web includes a non-linear profile in the axial direction providing the improved lateral stiffness. The method includes providing tooling including a first compression tool extending in the axial direction and including a first web portion having a non-linear profile, and a second compression tool extending in the axial direction and including a second web portion having a non-linear profile. Plies are placed within the tooling and compressed such that at least a portion of plurality of plies are compressed in the web forming portion thereby forming a web of the bulb stiffener having a non-linear profile.
    Type: Grant
    Filed: October 25, 2022
    Date of Patent: May 14, 2024
    Assignee: Spirit AeroSystems, Inc.
    Inventor: Mark Anthony Wadsworth
  • Patent number: 11969931
    Abstract: One embodiment of a method according to the present disclosure may use an outer member having the required structural rigidity and/or structural integrity such that no thermoforming tool, no support base, no fixture, no cover, no caul plate, no bag, and/or no table are required to make the part as desired. Substrate lay-up may be placed around all or a portion the outer member. A cover may be positioned over the outer member and the pressure within an interior portion of the outer member and cover may be reduced to less than ambient pressure and resin may be introduced to interact with the substrate lay-up and allowed to cure.
    Type: Grant
    Filed: July 15, 2019
    Date of Patent: April 30, 2024
    Assignee: Plastics Unlimited, inc.
    Inventors: Travis Kieffer, Terry Kieffer
  • Patent number: 11931968
    Abstract: A three-dimensionally laminated object modeling apparatus includes a cylinder configured to store a molten resin, a discharging nozzle that is communicated with the cylinder, and a piston configured to discharge the molten resin from the discharging nozzle by moving in a direction of approaching the discharging nozzle and by pressurizing the molten resin in the cylinder, and models a three-dimensionally modeled object by laminating a resin bead that is the molten resin discharged from the discharging nozzle on a table. It includes a drive device configured to relatively move the discharging nozzle with respect to the table and at least one processor configured to acquire a movement speed of the discharging nozzle and control movement of the piston based on the movement speed of the discharging nozzle.
    Type: Grant
    Filed: March 17, 2022
    Date of Patent: March 19, 2024
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventor: Yasuhiro Yamamoto
  • Patent number: 11931932
    Abstract: A mold assembly for producing a part includes a first section, a second section movably coupled to the first section, and a cavity defined by the first section and the second section, the cavity being shaped to receive a part while the first section and the second section are movably coupled to each other. The mold assembly includes a joint formed by adjacent surfaces of the first section and the second section and a seal extending along the joint.
    Type: Grant
    Filed: November 2, 2021
    Date of Patent: March 19, 2024
    Assignee: Thermwood Corporation
    Inventor: Kenneth J. Susnjara
  • Patent number: 11931927
    Abstract: A main object of the present invention is to provide beneficial improvements relating to a method for producing a fiber reinforced plastic product, the method including curing while pressurizing a prepreg preform by using a core having a fusible part as means for pressurizing.
    Type: Grant
    Filed: September 3, 2021
    Date of Patent: March 19, 2024
    Assignee: Mitsubishi Chemical Corporation
    Inventors: Satoshi Kaji, Tsuneo Takano, Takashi Honma
  • Patent number: 11926105
    Abstract: According to some aspects, techniques are described for generating support structures that may be easily removed after fabrication yet provide sufficient structural support during fabrication. In some cases, the techniques may include tuning an extent to which pillars of a support structure are interconnected to one another in regions proximate to the part. In some cases, the techniques may include fabricating very small contact structures, referred to herein as “hair” supports, in regions of a support structure where it connects with the part. In some cases, the techniques may include generating support structures that comprise obliquely-angled tips, which allow forces during fabrication to be applied in a preferred direction even when the support structure does not make a connection to the part in the preferred direction.
    Type: Grant
    Filed: March 31, 2020
    Date of Patent: March 12, 2024
    Assignee: Formlabs, Inc.
    Inventor: Benjamin FrantzDale
  • Patent number: 11926078
    Abstract: A method for creating a fan cowl with a hollow hat stiffener includes pressing a resin film between a non-crimp fabric (NCF) and a release poly-film to create a resin-fabric sheet. The method further includes cutting the resin-fabric sheet to a pre-determined shape to create at least one of a first resin-fabric preform, a second resin-fabric preform, and a third resin-fabric preform, draping at least the first resin-fabric preform over a tool to create an outer layer of the fan cowl, setting a mandrel over the outer layer, and draping the second resin-fabric preform over at least a portion of the mandrel and at least a portion of the first resin-fabric preform to form the hollow hat stiffener having a geometry similar to a shape of the mandrel.
    Type: Grant
    Filed: June 10, 2021
    Date of Patent: March 12, 2024
    Assignee: ROHR, INC
    Inventors: Bryan Thai, Delphine Turpin
  • Patent number: 11919260
    Abstract: A process for shaping, by compaction, a fibrous structure obtained by three-dimensional or multilayer weaving between a plurality of layers of warp yarns and a plurality of layers of weft yarns. The yarns of each plurality of layers of warp yarns and layers of weft yarns are coated with a sizing composition. The shaping includes a pre-compaction stage followed by a stage of final compaction of the fibrous structure. During pre-compaction and final compaction, the fibrous structure is at a temperature greater than or equal to the softening temperature of the sizing composition. The process further includes the cooling of the fibrous preform obtained after final compaction of the fibrous structure.
    Type: Grant
    Filed: August 27, 2019
    Date of Patent: March 5, 2024
    Assignee: SAFRAN
    Inventors: Christophe Ravey, Olivier Foussard, Nicolas Pierre Lanfant, Didier Payen, Adrien Touze, Romain Venat
  • Patent number: 11919242
    Abstract: A method for calibrating a 3D printer includes the steps of providing information obtained in a factory calibration indicating a center of an inner diameter of a tip orifice in a metal extrusion nozzle and a center of a tip surface for the nozzle and inductively sensing the nozzle with an eddy current sensor when secured to a print head on a gantry or robotic arm of the 3D printer to identify a sensed location of the center of the tip surface of the nozzle. The method includes determining a location of the center of the inner diameter of the tip orifice on the nozzle on the print head and utilizing the provided information to locate the center of the inner diameter of the tip orifice.
    Type: Grant
    Filed: December 27, 2021
    Date of Patent: March 5, 2024
    Assignee: Stratasys, Inc.
    Inventors: Michael Bosveld, Thomas Peter Paul