Patents by Inventor Brian G. Robins
Brian G. Robins 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: 20230066162Abstract: A composite forming apparatus includes an end effector and a forming feature that is coupled to the end effector. The end effector moves the forming feature relative to a forming tool to form a composite ply over a forming surface of the forming tool or over previously formed composite material on the forming surface of the forming tool. The composite forming apparatus further includes a positioning member engaged with the forming feature. The engagement between the positioning member and the forming feature facilitates a position between the forming feature and the composite ply to promote uniform application of compaction force over the forming surface of the forming tool.Type: ApplicationFiled: August 30, 2021Publication date: March 2, 2023Applicant: The Boeing CompanyInventors: Brian G. Robins, Kurtis S. Willden
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Publication number: 20230060932Abstract: A composite forming apparatus includes an end effector, a forming feature, and a non-contact heater. The forming feature is coupled to the end effector. The end effector moves the forming feature relative to a composite ply to form the composite ply over a forming tool or a prior formed composite ply. The non-contact heater heats to a portion of the composite ply before the portion of the composite ply is formed over the forming tool or the prior formed composite ply.Type: ApplicationFiled: August 30, 2021Publication date: March 2, 2023Applicant: The Boeing CompanyInventors: Kurtis S. Willden, Brian G. Robins, Steven M. Shewchuk, Brice A. Johnson
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Publication number: 20230063490Abstract: A method for forming a composite part includes positioning a composite ply over a forming surface of a forming tool, moving a forming feature into engagement with the composite ply to yield a formed ply, and, after the moving, securing the formed ply relative to the forming tool.Type: ApplicationFiled: August 30, 2021Publication date: March 2, 2023Applicant: The Boeing CompanyInventors: Kurtis S. Willden, Brian G. Robins
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Patent number: 10703055Abstract: A clamping system for securing a composite charge in position relative to a forming mandrel includes an upstream hinge clamp and a downstream hinge clamp for clamping opposing ends of the composite charge in respective position relative to a mandrel upstream end and a mandrel downstream end during forming of the composite charge onto the forming mandrel. Each one of the hinge clamps is configured to fold a corresponding end of the composite charge from a generally approximately flat configuration to an angled configuration during forming of the composite charge onto the forming mandrel. At least one of the hinge axes is oriented approximately parallel to a folding axis located proximate an intersection of a mandrel top portion with at least one of opposing mandrel side surfaces.Type: GrantFiled: July 14, 2017Date of Patent: July 7, 2020Assignees: The Boeing Company, Applus Servicios TecnologicosInventors: Brian G. Robins, Derek Willis, Jordi Brufau Redondo, Maria Clemencia Corzo Rueda
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Patent number: 10688711Abstract: A blanket assembly for forming a composite charge onto a forming mandrel includes upper and lower heating blankets configured to have a composite charge slidable therebetween during translation along the forming mandrel. The blanket assembly has a pair of wedge elements with tapered sections that are each positionable between the lower heating blanket and the mandrel side surfaces. The wedge element top sides are inclined from the tapered section forward end to the tapered section aft end. The upper heating blanket exerts a blanket forming pressure for progressively forming the composite charge into the cross-sectional shape of the forming mandrel collectively defined by the mandrel side surfaces and wedge element top sides as the composite charge passes over the tapered sections of the blanket assembly. The wedge element top sides maintain the laterally outboard portions of the composite charge in approximately parallel relation to a level tangent to the mandrel top portion.Type: GrantFiled: July 14, 2017Date of Patent: June 23, 2020Assignees: The Boeing Company, Applus Servicios TecnologicosInventors: Brian G. Robins, Ivan Berrios, Jordi Brufau Redondo, Maria Clemencia Corzo Rueda
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Patent number: 10286577Abstract: A composite mandrel includes a generally elongated mandrel body comprising a resilient mandrel core and an elastomeric mandrel outer layer disposed outside the mandrel core. A method for fabricating a contoured stiffened composite panel is also disclosed.Type: GrantFiled: May 2, 2016Date of Patent: May 14, 2019Assignee: The Boeing CompanyInventors: Brian G. Robins, Daniel M. Rotter, Todd J. Washburn, Panagiotis E. George
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Publication number: 20190016040Abstract: A blanket assembly for forming a composite charge onto a forming mandrel includes upper and lower heating blankets configured to have a composite charge slidable therebetween during translation along the forming mandrel. The blanket assembly has a pair of wedge elements with tapered sections that are each positionable between the lower heating blanket and the mandrel side surfaces. The wedge element top sides are inclined from the tapered section forward end to the tapered section aft end. The upper heating blanket exerts a blanket forming pressure for progressively forming the composite charge into the cross-sectional shape of the forming mandrel collectively defined by the mandrel side surfaces and wedge element top sides as the composite charge passes over the tapered sections of the blanket assembly. The wedge element top sides maintain the laterally outboard portions of the composite charge in approximately parallel relation to a level tangent to the mandrel top portion.Type: ApplicationFiled: July 14, 2017Publication date: January 17, 2019Inventors: Brian G. Robins, Ivan Berrios, Jordi Brufau Redondo, Maria Clemencia Corzo Rueda
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Publication number: 20190016069Abstract: A clamping system for securing a composite charge in position relative to a forming mandrel includes an upstream hinge clamp and a downstream hinge clamp for clamping opposing ends of the composite charge in respective position relative to a mandrel upstream end and a mandrel downstream end during forming of the composite charge onto the forming mandrel. Each one of the hinge clamps is configured to fold a corresponding end of the composite charge from a generally approximately flat configuration to an angled configuration during forming of the composite charge onto the forming mandrel. At least one of the hinge axes is oriented approximately parallel to a folding axis located proximate an intersection of a mandrel top portion with at least one of opposing mandrel side surfaces.Type: ApplicationFiled: July 14, 2017Publication date: January 17, 2019Inventors: Brian G. Robins, Derek Willis, Jordi Brufau Redondo, Maria Clemencia Corzo Rueda
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Patent number: 10155347Abstract: An apparatus for manufacturing composite parts. An expandable tool with a transfer system may be moved on a surface of the expandable tool into an outer mold line tool with a composite material laid up on the outer mold line tool. The expandable tool may be expanded in the outer mold line tool to change the surface from a retracted state to an expanded state. The transfer system may be transferred from the expandable tool with the surface in the expanded state to the outer mold line tool.Type: GrantFiled: May 6, 2016Date of Patent: December 18, 2018Assignee: The Boeing CompanyInventors: Joseph D. Brennan, Donald Chester Darrow, Kenneth M. Dull, William S. Hollensteiner, Jennifer Sue Noel, Brian G. Robins, Darrell D. Jones
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Patent number: 10052827Abstract: A composite layup is formed on a tool and placed on a contoured part. The tool is contoured to substantially match the contour of the part. A set of location data is generated which represents the location of the part in space relative to the tool. An automated manipulator uses the location data to move the tool into proximity to the part and place the contoured layup on the part.Type: GrantFiled: January 5, 2015Date of Patent: August 21, 2018Assignee: The Boeing CompanyInventors: Daniel M. Rotter, Kurtis S. Willden, William S. Hollensteiner, Brian G. Robins
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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: 20160263842Abstract: A composite layup is formed on a tool and placed on a contoured part. The tool is contoured to substantially match the contour of the part. A set of location data is generated which represents the location of the part in space relative to the tool. An automated manipulator uses the location data to move the tool into proximity to the part and place the contoured layup on the part.Type: ApplicationFiled: January 5, 2015Publication date: September 15, 2016Inventors: Daniel M. Rotter, Kurtis S. Willden, William S. Hollensteiner, Brian G. Robins
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Publication number: 20160243730Abstract: A composite mandrel includes a generally elongated mandrel body comprising a resilient mandrel core and an elastomeric mandrel outer layer disposed outside the mandrel core. A method for fabricating a contoured stiffened composite panel is also disclosed.Type: ApplicationFiled: May 2, 2016Publication date: August 25, 2016Inventors: Brian G. Robins, Daniel M. Rotter, Todd J. Washburn, Panagiotis E. George
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Publication number: 20160243768Abstract: An apparatus for manufacturing composite parts. An expandable tool with a transfer system may be moved on a surface of the expandable tool into an outer mold line tool with a composite material laid up on the outer mold line tool. The expandable tool may be expanded in the outer mold line tool to change the surface from a retracted state to an expanded state. The transfer system may be transferred from the expandable tool with the surface in the expanded state to the outer mold line tool.Type: ApplicationFiled: May 6, 2016Publication date: August 25, 2016Inventors: Joseph D. Brennan, Donald Chester Darrow, Kenneth M. Dull, William S. Hollensteiner, Jennifer Sue Noel, Brian G. Robins, Darrell D. Jones
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Patent number: 9387627Abstract: A hands-free method and related apparatus are used to shape, place and compact a composite stringer on a composite skin of an aircraft. A composite charge is placed on a tool assembly that used to shape the charge into a preformed stringer. With the stringer held on the tool assembly, the tool assembly is used to move the preformed stringer into proximity with the skin and both place and compact the stringer against the skin. Following compaction of the stringer, the tool assembly is removed and the skin and the stringer are co-cured.Type: GrantFiled: November 22, 2013Date of Patent: July 12, 2016Assignee: THE BOEING COMPANYInventors: Joseph D. Brennan, Darrell D. Jones, Brian G. Robins
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Patent number: 9346221Abstract: A method and apparatus for manufacturing composite parts. An expandable tool with a transfer system may be moved on a surface of the expandable tool into an outer mold line tool with a composite material laid up on the outer mold line tool. The expandable tool may be expanded in the outer mold line tool to change the surface from a retracted state to an expanded state. The transfer system may be transferred from the expandable tool with the surface in the expanded state to the outer mold line tool.Type: GrantFiled: December 19, 2008Date of Patent: May 24, 2016Assignee: THE BOEING COMPANYInventors: Joseph D. Brennan, Donald Chester Darrow, Kenneth M. Dull, William S. Hollensteiner, Jennifer Sue Noel, Brian G. Robins, Darrell D Jones
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Patent number: 9327467Abstract: A composite mandrel includes a generally elongated mandrel body comprising a resilient mandrel core and an elastomeric mandrel outer layer disposed outside the mandrel core. A method for fabricating a contoured stiffened composite panel is also disclosed.Type: GrantFiled: July 10, 2008Date of Patent: May 3, 2016Assignee: THE BOEING COMPANYInventors: Brian G. Robins, Daniel M. Rotter, Todd J. Washburn, Panagiotis E. George
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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: 9238335Abstract: A mandrel used to cure a composite part layup has an elastic body and at least one internal open space therein. The internal open space is configured to allow substantially uniform thermal expansion of the body during curing.Type: GrantFiled: January 8, 2009Date of Patent: January 19, 2016Assignee: THE BOEING COMPANYInventors: Brian G. Robins, Kurtis Willden, Ethan W. Hunter, Nika McManus
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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