Patents by Inventor Brad A. Coxon
Brad A. Coxon 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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Patent number: 11820081Abstract: Systems and methods for assembling elongate composite structures are disclosed. The systems include a first rigid elongate cure tool defining a first elongate support surface for supporting a first elongate charge of composite material (FEC), a second rigid elongate cure tool defining a second elongate support surface for supporting a second elongate charge of composite material (SEC), and a flexible elongate caul plate. The systems further include a vacuum compaction film, a translation structure, and a vacuum source. Methods according to the present disclosure include positioning a vacuum compaction film, positioning a flexible elongate caul plate, and positioning an FEC. The methods further include positioning an SEC, contacting a region of the FEC with a region of the SEC, sealing the vacuum compaction film, evacuating the enclosed volume to generate an elongate composite assembly, and heating the elongate composite assembly to define the elongate composite structure.Type: GrantFiled: August 9, 2021Date of Patent: November 21, 2023Assignee: The Boeing CompanyInventors: Daniel M. Rotter, Brad A. Coxon, Gabriel Zane Forston, Jake Adam Reeves, Khanh Mai Pham, Stephen Lee Metschan, Patrick Shephard, John Dempsey Morris, Steven Philip Hansen, Brian Dodgson
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Publication number: 20210362481Abstract: Systems and methods for assembling elongate composite structures are disclosed. The systems include a first rigid elongate cure tool defining a first elongate support surface for supporting a first elongate charge of composite material (FEC), a second rigid elongate cure tool defining a second elongate support surface for supporting a second elongate charge of composite material (SEC), and a flexible elongate caul plate. The systems further include a vacuum compaction film, a translation structure, and a vacuum source. Methods according to the present disclosure include positioning a vacuum compaction film, positioning a flexible elongate caul plate, and positioning an FEC. The methods further include positioning an SEC, contacting a region of the FEC with a region of the SEC, sealing the vacuum compaction film, evacuating the enclosed volume to generate an elongate composite assembly, and heating the elongate composite assembly to define the elongate composite structure.Type: ApplicationFiled: August 9, 2021Publication date: November 25, 2021Inventors: Daniel M. Rotter, Brad A. Coxon, Gabriel Zane Forston, Jake Adam Reeves, Khanh Mai Pham, Stephen Lee Metschan, Patrick Shephard, John Dempsey Morris, Steven Philip Hansen, Brian Dodgson
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Patent number: 11104113Abstract: Systems and methods for assembling elongate composite structures are disclosed. The systems include a first rigid elongate cure tool defining a first elongate support surface for supporting a first elongate charge of composite material (FEC), a second rigid elongate cure tool defining a second elongate support surface for supporting a second elongate charge of composite material (SEC), and a flexible elongate caul plate. The systems further include a vacuum compaction film, a translation structure, and a vacuum source. Methods according to the present disclosure include positioning a vacuum compaction film, positioning a flexible elongate caul plate, and positioning an FEC. The methods further include positioning an SEC, contacting a region of the FEC with a region of the SEC, sealing the vacuum compaction film, evacuating the enclosed volume to generate an elongate composite assembly, and heating the elongate composite assembly to define the elongate composite structure.Type: GrantFiled: April 19, 2017Date of Patent: August 31, 2021Assignee: The Boeing CompanyInventors: Daniel M. Rotter, Brian Dodgson, Brad A. Coxon, Gabriel Zane Forston, Jake Adam Reeves, Khanh Mai Pham, Stephen Lee Metschan, Patrick Shephard, John Dempsey Morris, Steven Philip Hansen
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Publication number: 20210069753Abstract: A cleaning system and a method for cleaning a surface of a ferromagnetic object are disclosed. Accordingly, to an example configuration, the cleaning system includes a device body having a guide face configured for selective placement against the surface. The device body comprises a magnetic system generating a magnetic field configured to urge the guide face against the surface of the ferromagnetic object by a magnetic force. The cleaning system further includes a scraper blade projecting outward from the device body to contact the surface upon placement of the guide face against the surface. The guide face may optionally comprise an outward-facing abrasive surface.Type: ApplicationFiled: September 10, 2019Publication date: March 11, 2021Inventors: Daniel M. Rotter, Brad A. Coxon, Kin Ung, Christopher Vernon Grubbs, James Isaac Hart, III, Johnny Hong
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Publication number: 20210069868Abstract: A cleaning system and a method for cleaning a surface of a ferromagnetic object are disclosed. Accordingly, to an example configuration, the cleaning system includes a device body that comprises a magnetic system that urges an abrasive layer against the surface of the ferromagnetic object by a magnetic force. In at least some examples, the magnetic force provided by the magnetic system is adjustable to achieve a target magnetic force for cleaning the surface.Type: ApplicationFiled: September 10, 2019Publication date: March 11, 2021Inventors: Daniel M. Rotter, Brad A. Coxon, Daniel J. McMillan, Christopher Vernon Grubbs, James Isaac Hart, III, Kin Ung
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Patent number: 10919240Abstract: An example system for processing composite material includes a cure tool, a source of pressurized gas, and a vacuum bag forming an enclosed volume between the cure tool and the vacuum bag. The system further includes composite material positioned on the cure tool within the enclosed volume. The source of pressurized gas is configured to inflate the vacuum bag, thereby moving a portion of the vacuum bag away from the cure tool and the composite material. An example method includes placing composite material onto a cure tool, placing a vacuum bag over the composite material and the cure tool to form an enclosed volume between the cure tool and the vacuum bag, processing the composite material while the composite material is within the enclosed volume, and inflating the vacuum bag to move a portion of the vacuum bag away from the cure tool and the composite material.Type: GrantFiled: February 22, 2018Date of Patent: February 16, 2021Assignee: THE BOEING COMPANYInventors: Daniel M. Rotter, Brad A. Coxon, Patrick J. Shephard, Nicholas W. Deyo, Darren L. Syverson, Aleksandr A. Khomyak, Martin P. Fritzgerald, Erik M. Brazil, Harrison B. Lockhart, III
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Publication number: 20190255786Abstract: An example system for processing composite material includes a cure tool, a source of pressurized gas, and a vacuum bag forming an enclosed volume between the cure tool and the vacuum bag. The system further includes composite material positioned on the cure tool within the enclosed volume. The source of pressurized gas is configured to inflate the vacuum bag, thereby moving a portion of the vacuum bag away from the cure tool and the composite material. An example method includes placing composite material onto a cure tool, placing a vacuum bag over the composite material and the cure tool to form an enclosed volume between the cure tool and the vacuum bag, processing the composite material while the composite material is within the enclosed volume, and inflating the vacuum bag to move a portion of the vacuum bag away from the cure tool and the composite material.Type: ApplicationFiled: February 22, 2018Publication date: August 22, 2019Inventors: Daniel M. Rotter, Brad A. Coxon, Patrick J. Shephard, Nicholas W. Deyo, Darren L. Syverson, Aleksandr A. Khomyak, Martin P. Fritzgerald, Erik M. Brazil, Harrison B. Lockhart, III
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Publication number: 20180304606Abstract: Systems and methods for assembling elongate composite structures are disclosed. The systems include a first rigid elongate cure tool defining a first elongate support surface for supporting a first elongate charge of composite material (FEC), a second rigid elongate cure tool defining a second elongate support surface for supporting a second elongate charge of composite material (SEC), and a flexible elongate caul plate. The systems further include a vacuum compaction film, a translation structure, and a vacuum source. Methods according to the present disclosure include positioning a vacuum compaction film, positioning a flexible elongate caul plate, and positioning an FEC. The methods further include positioning an SEC, contacting a region of the FEC with a region of the SEC, sealing the vacuum compaction film, evacuating the enclosed volume to generate an elongate composite assembly, and heating the elongate composite assembly to define the elongate composite structure.Type: ApplicationFiled: April 19, 2017Publication date: October 25, 2018Inventors: Daniel M. Rotter, Brad A. Coxon, Gabriel Zane Forston, Jake Adam Reeves, Khanh Mai Pham, Stephen Lee Metschan, Patrick Shephard, John Dempsey Morris, Steven Philip Hansen, Brian Dodgson
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Patent number: 9994008Abstract: System and method for compacting a composite ply layup comprising a forming tool comprising a top surface and a composite ply layup laid up along the top surface of the forming tool. A single release film comprising a top surface and a bottom surface, wherein the bottom surface of the single release film comprises a first non-planar bottom surface. The first non-planar bottom surface placed over a top surface of the composite ply layup. A venting port operatively coupled directly to the top surface of the single release film. A vacuum source operatively coupled to the venting port and configured to generate a vacuum to the single release film, such that the first non-planar bottom surface of the single release film defines a breather path for the vacuum generated by the vacuum source to distribute over the top surface of the composite ply layup.Type: GrantFiled: September 19, 2014Date of Patent: June 12, 2018Assignee: The Boeing CompanyInventors: Brad Coxon, Kurtis Willden
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Patent number: 9782960Abstract: A method and apparatus for compacting composite stringers. In one illustrative embodiment, an apparatus comprises a compacting structure, a compactor vacuum system, and a carrier vacuum system. The compacting structure has a shape configured to contact layers of uncured composite material for a composite stringer. The compactor vacuum system is associated with the compacting structure. The compactor vacuum system is configured to cause the compacting structure to apply a pressure to the layers of uncured composite material when a compactor vacuum is applied to the compactor vacuum system. The carrier vacuum system is associated with the compacting structure. The carrier vacuum system is configured to hold the layers of uncured composite material against the compacting structure when a carrier vacuum is applied to the carrier vacuum system.Type: GrantFiled: February 29, 2016Date of Patent: October 10, 2017Assignee: The Boeing CompanyInventors: Brian G. Robins, Kurtis S. Willden, Daniel M. Rotter, Brad A. Coxon
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Publication number: 20160082710Abstract: System and method for compacting a composite ply layup comprising a forming tool comprising a top surface and a composite ply layup laid up along the top surface of the forming tool. A single release film comprising a top surface and a bottom surface, wherein the bottom surface of the single release film comprises a first non-planar bottom surface. The first nonplanar bottom surface placed over a top surface of the composite ply layup. A venting port operatively coupled directly to the top surface of the single release film. A vacuum source operatively coupled to the venting port and configured to generate a vacuum to the single release film, such that the first non-planar bottom surface of the single release film defines a breather path for the vacuum generated by the vacuum source to distribute over the top surface of the composite ply layup.Type: ApplicationFiled: September 19, 2014Publication date: March 24, 2016Inventors: Brad Coxon, Kurtis Willden
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Patent number: 9272495Abstract: A method and apparatus for compacting composite stringers. In one illustrative embodiment, an apparatus comprises a compacting structure, a compactor vacuum system, and a carrier vacuum system. The compacting structure has a shape configured to contact layers of uncured composite material for a composite stringer. The compactor vacuum system is associated with the compacting structure. The compactor vacuum system is configured to cause the compacting structure to apply a pressure to the layers of uncured composite material when a compactor vacuum is applied to the compactor vacuum system. The carrier vacuum system is associated with the compacting structure. The carrier vacuum system is configured to hold the layers of uncured composite material against the compacting structure when a carrier vacuum is applied to the carrier vacuum system.Type: GrantFiled: September 25, 2012Date of Patent: March 1, 2016Assignee: THE BOEING COMPANYInventors: Brian G. Robins, Kurtis S. Willden, Daniel M. Rotter, Brad A. Coxon
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Patent number: 9254619Abstract: Method and tooling apparatus for forming a composite charge into a contoured composite blade stringer including an elongate punch and an elongate die flexible along their lengths. The charge is press formed by using the punch to drive the charge into the die. The punch and the die are mounted between a pair of flexible plates. A press coupled with the plates contours the charge by bending the plates into a desired contour. The stringer is allowed to cool down to room temperature while being constrained, before withdrawing the stringer from the tooling apparatus in order to reduce wrinkling.Type: GrantFiled: June 13, 2013Date of Patent: February 9, 2016Assignee: THE BOEING COMPANYInventors: Daniel M. Rotter, Michael R. Chapman, Brad A. Coxon, Paul E. Nelson, Khanh M. Pham
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Patent number: 9221235Abstract: Methods of assembling a stiffened composite structure include loading a stiffener onto an inner mold line layup mandrel; positioning a filler structure on an upper side of a filler location tool; following the loading and the positioning, locating, with the filler location tool, the filler structure within the stiffener cavity of the stiffener; repeating the loading, the positioning, and the locating to load a plurality of stiffeners and filler structures; and following the repeating, affixing a skin segment over the plurality of filler structures and to the plurality of stiffeners to form at least a portion of the stiffened composite structure. Systems for assembling stiffened composite structures include a supply of stiffeners; a supply of filler structures; an inner mold line layup mandrel; and a filler location tool configured to locate a filler structure within the stiffener cavity of a stiffener that is loaded onto the mandrel.Type: GrantFiled: January 2, 2013Date of Patent: December 29, 2015Assignee: The Boeing CompanyInventors: Daniel M. Rotter, Brad A. Coxon, Brian G. Robins
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Patent number: 9199418Abstract: Systems and methods for assembling a skin of a composite structure on an outer surface of an inner mold line layup mandrel. The systems and methods include receiving a plurality of ply kits, assembling the plurality of ply kits to form a skin segment that defines a portion of the skin, and affixing the skin segment to the outer surface of the layup mandrel. The assembling includes transferring a respective ply kit of the plurality of ply kits to a non-planar transfer tool, compacting the respective ply kit on the non-planar transfer tool, and repeating the transferring and the compacting for each ply kit in the plurality of ply kits to form the skin segment.Type: GrantFiled: January 23, 2015Date of Patent: December 1, 2015Assignee: The Boeing CompanyInventors: Daniel M. Rotter, Paul Chih-Yung Chang, Brad A. Coxon, Paul E. Nelson, Kimberlee Madden, Henry Macias, Jennifer Sue Noel, Eugene H. Jeppesen, Kurtis S. Willden, Arvid J. Berg, Richard V. Phillips, Stephen Lee Metschan, Stephen K. Kirchmeier, Joseph D. Anderson, Scott A. Boner
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Patent number: 9199417Abstract: Methods of assembling a stiffened composite structure include loading, with a stiffener loading tool, a respective stiffener from a supply of stiffeners onto an inner mold line layup mandrel; repeating the loading to load a plurality of stiffeners onto the inner mold line layup mandrel; and following the repeating, affixing a respective skin segment from a supply of skin segments to the plurality of stiffeners loaded on the inner mold line layup mandrel to form at least a portion of the stiffened composite structure. Systems for assembling stiffened composite structures include a supply of stiffeners; an inner mold line layup mandrel; and a stiffener loading tool configured to load the respective stiffener onto the inner mold line layup mandrel.Type: GrantFiled: January 2, 2013Date of Patent: December 1, 2015Assignee: The Boeing CompanyInventors: Daniel M. Rotter, Jennifer Sue Noel, Brian G. Robins, Kimberlee Madden, Henry Macias, Brad A. Coxon, Stephen K. Kirchmeier, Joseph D. Anderson, Kurtis S. Willden
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Patent number: 8974618Abstract: Systems and methods for assembling a skin of a composite structure on an outer surface of an inner mold line layup mandrel. The systems and methods include receiving a plurality of ply kits, assembling the plurality of ply kits to form a skin segment that defines a portion of the skin, and affixing the skin segment to the outer surface of the layup mandrel. The assembling includes transferring a respective ply kit of the plurality of ply kits to a non-planar transfer tool, compacting the respective ply kit on the non-planar transfer tool, and repeating the transferring and the compacting for each ply kit in the plurality of ply kits to form the skin segment.Type: GrantFiled: December 4, 2012Date of Patent: March 10, 2015Assignee: The Boeing CompanyInventors: Daniel M. Rotter, Paul Chih-Yung Chang, Brad A. Coxon, Paul E. Nelson, Kimberlee Madden, Henry Macias, Jennifer Sue Noel, Eugene H. Jeppesen, Kurtis S. Willden, Arvid J. Berg, Richard V. Phillips, Stephen Lee Metschan, Stephen K. Kirchmeier, Joseph D. Anderson, Scott A. Boner
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Publication number: 20130340928Abstract: Method and tooling apparatus for forming a composite charge into a contoured composite blade stringer including an elongate punch and an elongate die flexible along their lengths. The charge is press formed by using the punch to drive the charge into the die. The punch and the die are mounted between a pair of flexible plates. A press coupled with the plates contours the charge by bending the plates into a desired contour. The stringer is allowed to cool down to room temperature while being constrained, before withdrawing the stringer from the tooling apparatus in order to reduce wrinkling.Type: ApplicationFiled: June 13, 2013Publication date: December 26, 2013Inventors: Daniel M. Rotter, Michael R. Chapman, Brad A. Coxon, Paul E. Nelson, Khanh M. Pham
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Patent number: 8465613Abstract: Tooling apparatus for forming a composite charge into a contoured composite blade stringer includes an elongate punch and an elongate die flexible along their lengths. The charge is press formed by using the punch to drive the charge into the die. The punch and the die are mounted between a pair of flexible plates. A press coupled with the plates contours the charge by bending the plates into a desired contour.Type: GrantFiled: August 24, 2011Date of Patent: June 18, 2013Assignee: The Boeing CompanyInventors: Daniel M. Rotter, Michael R. Chapman, Brad A. Coxon, Paul E. Nelson
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Publication number: 20130049258Abstract: Tooling apparatus for forming a composite charge into a contoured composite blade stringer includes an elongate punch and an elongate die flexible along their lengths. The charge is press formed by using the punch to drive the charge into the die. The punch and the die are mounted between a pair of flexible plates. A press coupled with the plates contours the charge by bending the plates into a desired contour.Type: ApplicationFiled: August 24, 2011Publication date: February 28, 2013Applicant: THE BOEING COMPANYInventors: Daniel M. Rotter, Michael R. Chapman, Brad A. Coxon, Paul E. Nelson