Patents by Inventor Benedict N. Hodgson
Benedict N. Hodgson 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: 20230351995Abstract: The disclosure describes acoustic panels (such as for gas turbine engines) and techniques for forming acoustic panels. In some examples, the acoustic panel comprises a coversheet comprising an outer face, an inner face, and a plurality of apertures extend from the outer face to the inner face. The acoustic panel also comprises a 3D printed support layer comprising a polymer and defining a plurality of cell openings, wherein a first side of the support layer opposite the cell openings is coincident with the inner face of the coversheet, and wherein the 3D printed support layer is 3D printed directly onto the inner face of the coversheet.Type: ApplicationFiled: April 29, 2022Publication date: November 2, 2023Inventors: Benedict N. Hodgson, Jeff Higbie
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Publication number: 20230258132Abstract: In some examples, acoustic panels (such as for gas turbine engines) and techniques for forming acoustic panels. In some examples, the acoustic panel including a coversheet including an outer face, an inner face, and a plurality of apertures extend from the outer face to the inner face. The acoustic panel also includes a 3D-printed support layer including a lattice structure formed at least partially of a polymer, the lattice structure defining a plurality of cells of the support layer, wherein a first side of the support layer is coincident with the inner face of the coversheet.Type: ApplicationFiled: February 14, 2022Publication date: August 17, 2023Inventors: Benedict N. Hodgson, Jeff Higbie
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Patent number: 11506083Abstract: Composite liners (such as acoustic panels, fan track liners, and/or ice impact panels or boxes for turbofan engines) and techniques for forming composite liners. In some examples, the composite liner includes at least one region comprising a reinforcement architecture comprising a matrix material, a plurality of relatively tough polymer-based reinforcement elements, and a plurality of second reinforcement elements. The plurality of relatively tough polymer-based reinforcement elements and the plurality of second reinforcement elements are embedded in the matrix material.Type: GrantFiled: June 3, 2020Date of Patent: November 22, 2022Assignee: Rolls-Royce CorporalionInventors: Matthew J. Kappes, Robert Heeter, Jonathan Michael Rivers, Benedict N. Hodgson
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Patent number: 11421538Abstract: A composite aerofoil may include an aerofoil body defining a leading edge and a trailing edge, wherein the body comprises a composite material including a plurality of relatively higher-modulus reinforcement elements, a plurality of relatively tougher polymer-based reinforcement elements, and a matrix material substantially encapsulating the plurality of relatively higher-modulus reinforcement elements and the plurality of relatively tougher polymer-based reinforcement elements. The plurality of relatively higher-modulus reinforcement elements are different from the plurality of relatively tougher polymer-based reinforcement elements. The disclosure also describes techniques for forming composite aerofoils.Type: GrantFiled: May 12, 2020Date of Patent: August 23, 2022Assignee: Rolls-Royce CorporationInventors: Robert Heeter, Matthew J. Kappes, Jonathan Michael Rivers, Benedict N. Hodgson
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Publication number: 20210381396Abstract: The disclosure describes composite liners (such as acoustic panels, fan track liners, and/or ice impact panels or boxes for turbofan engines) and techniques for forming composite liners. In some examples, the composite liner includes at least one region comprising a reinforcement architecture comprising a matrix material, a plurality of relatively tough polymer-based reinforcement elements, and a plurality of second reinforcement elements. The plurality of relatively tough polymer-based reinforcement elements and the plurality of second reinforcement elements are embedded in the matrix material.Type: ApplicationFiled: June 3, 2020Publication date: December 9, 2021Inventors: Matthew J. Kappes, Robert Heeter, Jonathan Michael Rivers, Benedict N. Hodgson
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Publication number: 20210355833Abstract: A composite aerofoil may include an aerofoil body defining a leading edge and a trailing edge, wherein the body comprises a composite material including a plurality of relatively higher-modulus reinforcement elements, a plurality of relatively tougher polymer-based reinforcement elements, and a matrix material substantially encapsulating the plurality of relatively higher-modulus reinforcement elements and the plurality of relatively tougher polymer-based reinforcement elements. The plurality of relatively higher-modulus reinforcement elements are different from the plurality of relatively tougher polymer-based reinforcement elements. The disclosure also describes techniques for forming composite aerofoils.Type: ApplicationFiled: May 12, 2020Publication date: November 18, 2021Inventors: Robert Heeter, Matthew J. Kappes, Jonathan Michael Rivers, Benedict N. Hodgson
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Patent number: 11078839Abstract: The disclosure describes composite nosecones and techniques for forming composite nosecones including a matrix material, relatively higher-modulus reinforcement elements, and relatively tougher polymer-based reinforcement elements. An example composite nosecone includes a body substantially symmetrical around a central axis. The body includes a side wall defining a diameter of the body that increases from a forward side of the body to an aft side of the body. The body includes a composite material including a plurality of relatively higher-modulus reinforcement elements, a plurality of relatively tougher polymer-based reinforcement elements, and a matrix material substantially encapsulating the plurality of relatively higher-modulus reinforcement elements and the plurality of relatively tougher polymer-based reinforcement elements. The plurality of relatively higher-modulus reinforcement elements are different from the plurality of relatively tougher polymer-based reinforcement elements.Type: GrantFiled: January 22, 2018Date of Patent: August 3, 2021Assignee: Rolls-Royce CorporationInventors: Robert Heeter, Matthew J. Kappes, Benedict N. Hodgson
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Patent number: 10641287Abstract: According to one aspect, a fan containment case for a gas turbine engine is provided which includes a barrel having a first band of material on an outside of the barrel. The first band is made of carbon fiber composite. The barrel further includes a second band of material inboard of the fan case and made of poly p-phenylene-2,6-benzobisoxazole (PBO) composite. The barrel also includes a third band of material made of carbon fiber composite inboard of the second band.Type: GrantFiled: September 6, 2016Date of Patent: May 5, 2020Assignee: Rolls-Royce CorporationInventors: Matthew J. Kappes, Robert W. Heeter, Benedict N. Hodgson
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Publication number: 20190226401Abstract: The disclosure describes composite nosecones and techniques for forming composite nosecones including a matrix material, relatively higher-modulus reinforcement elements, and relatively tougher polymer-based reinforcement elements. An example composite nosecone includes a body substantially symmetrical around a central axis. The body includes a side wall defining a diameter of the body that increases from a forward side of the body to an aft side of the body. The body includes a composite material including a plurality of relatively higher-modulus reinforcement elements, a plurality of relatively tougher polymer-based reinforcement elements, and a matrix material substantially encapsulating the plurality of relatively higher-modulus reinforcement elements and the plurality of relatively tougher polymer-based reinforcement elements. The plurality of relatively higher-modulus reinforcement elements are different from the plurality of relatively tougher polymer-based reinforcement elements.Type: ApplicationFiled: January 22, 2018Publication date: July 25, 2019Inventors: Robert Heeter, Matthew J. Kappes, Benedict N. Hodgson
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Patent number: 10174633Abstract: According to one aspect, a fan blade containment apparatus for turbofan engines includes a containment hook and a fan case barrel. The containment hook and the fan case barrel are formed from composite materials, and the containment hook is attached to the fan case barrel such that the containment hook contains forward motion of a fan blade during a fan blade off event. The apparatus further includes the containment hook being arranged to shorten the axial length of the fan case barrel.Type: GrantFiled: October 30, 2015Date of Patent: January 8, 2019Assignee: Rolls-Royce CorporationInventors: Christopher Hall, Benedict N. Hodgson
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Publication number: 20180066675Abstract: According to one aspect, a fan containment case for a gas turbine engine is provided which includes a barrel having a first band of material on an outside of the barrel. The first band is made of carbon fiber composite. The barrel further includes a second band of material inboard of the fan case and made of poly p-phenylene-2,6-benzobisoxazole (PBO) composite. The barrel also includes a third band of material made of carbon fiber composite inboard of the second band.Type: ApplicationFiled: September 6, 2016Publication date: March 8, 2018Inventors: Matthew J. Kappes, Robert W. Heeter, Benedict N. Hodgson
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Publication number: 20170122126Abstract: According to one aspect, a fan blade containment apparatus for turbofan engines includes a containment hook and a fan case barrel. The containment hook and the fan case barrel are formed from composite materials, and the containment hook is attached to the fan case barrel such that the containment hook contains forward motion of a fan blade during a fan blade off event. The apparatus further includes the containment hook being arranged to shorten the axial length of the fan case barrel.Type: ApplicationFiled: October 30, 2015Publication date: May 4, 2017Inventors: Christopher Hall, Benedict N. Hodgson
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Patent number: 9470097Abstract: A leading edge member for a composite vane of a gas turbine engine. The leading edge member includes a first leg and a second leg. The first leg includes a proximal end joined to a proximal end of the second leg.Type: GrantFiled: December 2, 2013Date of Patent: October 18, 2016Assignee: Rolls-Royce CorporationInventors: Benedict N. Hodgson, Jonathan M. Rivers
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Publication number: 20160017731Abstract: A compressor for a gas turbine engine includes a plurality of rotating wheel assemblies, a plurality of static vane assemblies, and a case extending around the rotating wheel assemblies and static vane assemblies. The static vane assemblies include an inner band, an outer band, and a plurality of vanes extending between the inner and outer bands.Type: ApplicationFiled: June 29, 2015Publication date: January 21, 2016Inventors: Jeffrey M. Becker, Michael C. Margetts, Benedict N. Hodgson, Danny E. McAdams, Rebecca M. Johnson
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Publication number: 20150044056Abstract: A leading edge member for a composite vane of a gas turbine engine. The leading edge member includes a first leg and a second leg. The first leg includes a proximal end joined to a proximal end of the second leg.Type: ApplicationFiled: December 2, 2013Publication date: February 12, 2015Inventors: Benedict N. Hodgson, Jonathan M. Rivers
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Patent number: 8764387Abstract: An aggregate vane assembly includes a core vane assembly encircling a central longitudinal axis and having a plurality of core vanes each extending radially between an inner hub and an outer band. The aggregate vane assembly also includes a bypass vane assembly disposed on a radially opposite side of the outer band relative to the plurality of core vanes. The aggregate vane assembly also includes a splitter ring positioned proximate to the first forward end. The aggregate vane assembly also includes at least one retention plate overlapping a forward end of the at least one bypass vane along the central longitudinal axis and also overlapping at least a portion of the splitter ring along the central longitudinal axis.Type: GrantFiled: January 25, 2011Date of Patent: July 1, 2014Assignee: Rolls-Royce CorporationInventors: Matthew Joseph Jordan, Eric W. Engebretsen, Benedict N. Hodgson
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Patent number: 8734606Abstract: A composite component includes an inner core formed from a first composite material having discontinuous fibers. An outer sleeve is formed from a second composite material different from the first, and having continuous fibers. The outer sleeve generally surrounds and is bonded or otherwise connected to the inner core. The component is made by injecting or otherwise introducing thermoplastic fiber composite material including chopped or otherwise discontinuous fibers into a mold to form the inner core having a first portion with smooth surfaces and integrally joined to a second portion with bumps and ridges. The injected thermoplastic fiber composite material is cured and then removed from the mold. A layup including one or more surface plies of a thermoset continuous fiber composite material is then applied to the smooth first portion of the core. The surface plies then are compressed and cured in a mold.Type: GrantFiled: October 16, 2012Date of Patent: May 27, 2014Assignee: Rolls-Royce CorporationInventors: Jeffrey P. Henkle, Benedict N. Hodgson
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Patent number: 8348604Abstract: An airfoil or vane for a combustive power plant includes an inner core formed from a first composite material having discontinuous fibers. An outer sleeve is formed from a second composite material having continuous fibers. The first composite material is different from the second composite material. The outer sleeve generally surrounds and is bonded or otherwise connected to the inner core. A method of fabrication includes injecting or otherwise introducing thermoplastic fiber composite material including chopped or otherwise discontinuous fibers into a mold to form the core and platforms of an airfoil assembly. The injected thermoplastic fiber composite material is then cured in the mold. The cured thermoplastic fiber composite material is then removed from the mold. A layup including one or more surface plies of a thermoset continuous fiber composite material is then applied to the core material. The surface plies are then compressed and cured in a mold.Type: GrantFiled: March 17, 2008Date of Patent: January 8, 2013Assignee: Rolls-Royce CorporationInventors: Jeffrey P. Henkle, Benedict N. Hodgson
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Publication number: 20120189432Abstract: An aggregate vane assembly is disclosed herein. The aggregate vane assembly includes a core vane assembly encircling a central longitudinal axis and having a plurality of core vanes each extending radially between an inner hub and an outer band. The core vane assembly extends along the central longitudinal axis between a first forward end and a first aft end. The aggregate vane assembly also includes a bypass vane assembly disposed on a radially opposite side of the outer band relative to the plurality of core vanes. The bypass vane assembly includes at least one bypass vane extending radially outward from a platform. The bypass vane assembly extends along the central longitudinal axis between a second forward end and a second aft end. The aggregate vane assembly also includes a splitter ring positioned proximate to the first forward end.Type: ApplicationFiled: January 25, 2011Publication date: July 26, 2012Inventors: MATTHEW JOSEPH JORDAN, Eric W. Engebretsen, Benedict N. Hodgson
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Publication number: 20090232647Abstract: An airfoil or vane for a combustive power plant includes an inner core formed from a first composite material having discontinuous fibers. An outer sleeve is formed from a second composite material having continuous fibers. The first composite material is different from the second composite material. The outer sleeve generally surrounds and is bonded or otherwise connected to the inner core. A method of fabrication includes injecting or otherwise introducing thermoplastic fiber composite material including chopped or otherwise discontinuous fibers into a mold to form the core and platforms of an airfoil assembly. The injected thermoplastic fiber composite material is then cured in the mold. The cured thermoplastic fiber composite material is then removed from the mold. A layup including one or more surface plies of a thermoset continuous fiber composite material is then applied to the core material. The surface plies are then compressed and cured in a mold.Type: ApplicationFiled: March 17, 2008Publication date: September 17, 2009Inventors: Jeffrey P. Henkle, Benedict N. Hodgson