Patents by Inventor Carl R. Verner

Carl R. Verner 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).

  • Publication number: 20200086383
    Abstract: A conveyor furnace system is provided that includes a housing, a conveyor, a vacuum device, and at least one heating element. The housing may have a first end and a second end. The conveyor may be configured to transit one or more component molds from the first end to the second end. The vacuum device may be configured to selectively produce a below atmospheric pressure within the housing. The at least one heating element may be disposed in the housing, and has a first end disposed adjacent the first end of the housing and a second end adjacent the second end of the housing. The at least one heating element is configured to provide a vertically tapered heating exposure in a direction from the first end of the housing to the second end of the housing.
    Type: Application
    Filed: September 14, 2018
    Publication date: March 19, 2020
    Inventors: Steven J. Bullied, Carl R. Verner, Grant Rubin, Andrew Boyne
  • Patent number: 10569327
    Abstract: A die casting system includes a die including at least one die component that defines a die cavity, a spar received within a portion of said die cavity, a shot tube in fluid communication with the die cavity, and a shot tube plunger moveable within the shot tube to communicate a molten metal into the die cavity to cast a hybrid component. The spar establishes an internal structure of the hybrid component, and one of the internal structures and an outer structure of said hybrid component is an equiaxed structure.
    Type: Grant
    Filed: February 9, 2018
    Date of Patent: February 25, 2020
    Assignee: United Technologies Corporation
    Inventors: Steven J. Bullied, John Joseph Marcin, Carl R. Verner
  • Publication number: 20200025467
    Abstract: A method of forming a cast heat exchanger plate includes forming at least one hot core plate defining internal features of a one piece heat exchanger plate and at least one first set of interlocking features. At least one cold core plate is formed defining external features of the heat exchanger plate and at least one second set of interlocking features. A core assembly is assembled wherein each hot core plate is directly interlocked to the at least one cold core plate. A wax pattern is formed with the core assembly. An external shell is formed over the wax pattern. The wax pattern is removed to form a space between the core assembly and the external shell. The space is filled with a molten material and cures the molten material. The external shell is removed. The core assembly is removed. A core assembly for a cast heat exchanger is also disclosed.
    Type: Application
    Filed: February 8, 2019
    Publication date: January 23, 2020
    Inventors: Michael A. Disori, Carl R. Verner, Steven J. Bullied, David Donald Chapdelaine
  • Publication number: 20190323787
    Abstract: A heat exchanger is disclosed and includes a plate portion including a plurality of internal passages extending between an inlet and an outlet and at least one means for providing fluid communication between at least two of the plurality of internal passages.
    Type: Application
    Filed: February 21, 2019
    Publication date: October 24, 2019
    Inventors: Wililam P. Stillman, Michael A. Disori, Dave J. Hyland, Carl R. Verner
  • Patent number: 10449605
    Abstract: A method casts a plurality of alloy parts in a mold (600; 700) having a plurality of part-forming cavities (601). The method comprises pouring a first alloy into the mold causing: the first alloy to branch into respective flows along respective first flowpaths (676, 684; 708) to the respective cavities; and a surface of the first alloy in the part-forming cavities to equilibrate. The method further comprises pouring a second alloy into the mold causing: the second alloy to branch into respective flows along respective second flowpaths (676, 680; 712) to the respective cavities.
    Type: Grant
    Filed: November 7, 2014
    Date of Patent: October 22, 2019
    Assignee: United Technologies Corporation
    Inventors: Steven J. Bullied, John J. Marcin, Jr., Emily K. Kreek, Carl R. Verner, Mario P. Bochiechio
  • Publication number: 20190299278
    Abstract: An example die casting system includes a die comprised of a plurality of die components that define a die cavity configured to receive a molten metal. One of the die components comprises a material that is not reactive with the molten metal and has a melting temperature above 815 degrees Celsius. The die casting system may be used in a method for die casting a gas turbine engine component.
    Type: Application
    Filed: April 15, 2019
    Publication date: October 3, 2019
    Inventors: Mario P. BOCHIECHIO, Dilip M. SHAH, Lea Kennard CASTLE, Douglas M. BERCZIK, John Joseph MARCIN, Carl R. VERNER
  • Publication number: 20190293365
    Abstract: A cast part includes an outermost wall, at least one inner wall defining at least two internal passages and at least one cast cooling fin extending from an outer surface. The cooling fin includes a ratio of fin height to an average fin thickness that is greater than 2.0 and no more than 18.0. A method is also disclosed.
    Type: Application
    Filed: February 8, 2019
    Publication date: September 26, 2019
    Inventors: Michael A. Disori, Steven J. Bullied, Ryan C. Breneman, John Marcin, David J. Hyland, William P. Stillman, Carl R. Verner
  • Patent number: 10369625
    Abstract: A method for casting comprising: providing a seed, the seed characterized by: an arcuate form and a crystalline orientation progressively varying along an arc of the form; providing molten material; and cooling and solidifying the molten material so that a crystalline structure of the seed propagates into the solidifying material.
    Type: Grant
    Filed: June 5, 2015
    Date of Patent: August 6, 2019
    Assignee: United Technologies Corporation
    Inventors: Dilip M. Shah, Paul D. Genereux, Alan D. Cetel, John J. Marcin, Jr., Steven J. Bullied, Mario P. Bochiechio, Kevin W. Schlichting, Bradford A. Cowles, Carl R. Verner, David U. Furrer, Venkatarama K. Seetharaman
  • Patent number: 10315241
    Abstract: A method comprises: providing a spiral metallic workpiece having a cast structure associated with such spiral; and at least partially flattening the workpiece.
    Type: Grant
    Filed: June 24, 2015
    Date of Patent: June 11, 2019
    Assignee: United Technologies Corporation
    Inventors: Dilip M. Shah, Alan D. Cetel, John J. Marcin, Jr., Steven J. Bullied, Carl R. Verner
  • Publication number: 20190143392
    Abstract: A method comprises: providing a spiral metallic workpiece having a cast structure associated with such spiral; and at least partially flattening the workpiece.
    Type: Application
    Filed: January 11, 2019
    Publication date: May 16, 2019
    Applicant: United Technologies Corporation
    Inventors: Dilip M. Shah, Alan D. Cetel, John J. Marcin, JR., Steven J. Bullied, Carl R. Verner
  • Patent number: 10265763
    Abstract: A method for casting comprising: providing a seed, the seed characterized by: an arcuate form and a crystalline orientation progressively varying along an arc of the form; providing molten material; and cooling and solidifying the molten material so that a crystalline structure of the seed propagates into the solidifying material.
    Type: Grant
    Filed: October 5, 2018
    Date of Patent: April 23, 2019
    Assignee: United Technologies Corporation
    Inventors: Dilip M. Shah, Paul D. Genereux, Alan D. Cetel, John J. Marcin, Jr., Steven J. Bullied, Mario P. Bochiechio, Kevin W. Schlichting, Bradford A. Cowles, Carl R. Verner, David U. Furrer, Venkatarama K. Seetharaman
  • Patent number: 10245637
    Abstract: Shot sleeves for high temperature die casting include a nickel-based alloy having a low modulus single crystal with axi-symmetric orientation.
    Type: Grant
    Filed: August 26, 2016
    Date of Patent: April 2, 2019
    Assignee: UNITED TECHNOLOGIES CORPORATION
    Inventors: John Joseph Marcin, Dilip M. Shah, Carl R. Verner, Albert Rabinovich, Weiduo Yu, Thomas N. Slavens
  • Publication number: 20190039128
    Abstract: A method for casting comprising: providing a seed, the seed characterized by: an arcuate form and a crystalline orientation progressively varying along an arc of the form; providing molten material; and cooling and solidifying the molten material so that a crystalline structure of the seed propagates into the solidifying material.
    Type: Application
    Filed: October 5, 2018
    Publication date: February 7, 2019
    Applicant: United Technologies Corporation
    Inventors: Dilip M. Shah, Paul D. Genereux, Alan D. Cetel, John J. Marcin, JR., Steven J. Bullied, Mario P. Bochiechio, Kevin W. Schlichting, Bradford A. Cowles, Carl R. Verner, David U. Furrer, Venkatarama K. Seetharaman
  • Patent number: 10173261
    Abstract: A die casting plunger tip includes a hollow outer portion and a hollow inner portion. The outer portion has a first closed end. The inner portion has a second partially closed end. The inner portion is disposed within the outer portion and the second partially closed end is adjacent the first closed end of the outer portion in an axial direction. A plurality of connectors connects the outer portion and the inner portion. A plenum is formed between the outer portion and the inner portion.
    Type: Grant
    Filed: November 23, 2015
    Date of Patent: January 8, 2019
    Assignee: United Technologies Corporation
    Inventors: Thomas N. Slavens, Carl R. Verner, Albert Rabinovich, Weiduo Yu, Awadh B. Pandey
  • Patent number: 10024181
    Abstract: A casting mold assembly includes an airfoil defining section and a casting core. The airfoil defining section includes an outer mold wall and a direct-shelled inner mold wall. The direct-shelled inner mold wall is disposed within a forward chordwise portion of the airfoil defining section. The direct-shelled inner mold wall includes an aft end having an external radius measuring more than about 0.075 in. (1.9 mm). The casting core is secured within an aft chordwise portion of the airfoil defining section, and includes an aft end with an external radius measuring less than about 0.075 in. (1.9 mm). A cast component and a method for making the casting mold assembly are also disclosed.
    Type: Grant
    Filed: October 5, 2016
    Date of Patent: July 17, 2018
    Assignee: United Technologies Corporation
    Inventors: Steven J. Bullied, Carl R. Verner, Steven D. Porter, James B. Park
  • Publication number: 20180161862
    Abstract: A die casting system includes a die including at least one die component that defines a die cavity, a spar received within a portion of said die cavity, a shot tube in fluid communication with the die cavity, and a shot tube plunger moveable within the shot tube to communicate a molten metal into the die cavity to cast a hybrid component. The spar establishes an internal structure of the hybrid component, and one of the internal structures and an outer structure of said hybrid component is an equiaxed structure.
    Type: Application
    Filed: February 9, 2018
    Publication date: June 14, 2018
    Inventors: Steven J. Bullied, John Joseph Marcin, Carl R. Verner
  • Publication number: 20180117670
    Abstract: A shot tube includes an inner bore for delivering molten material into a die-cast mold. The shot tube has an outer peripheral surface with at least one surface for receiving a locking member to lock the shot tube into an aperture in a fixed mold portion and an alignment structure for properly aligning the shot tube in the fixed mold portion. An opening receives molten material into the inner bore.
    Type: Application
    Filed: December 22, 2017
    Publication date: May 3, 2018
    Inventors: Mario P. Bochiechio, Yee Ling Kwan, Carl R. Verner
  • Patent number: 9925584
    Abstract: A method for die casting a hybrid component includes defining a cavity within a die element of a die and inserting a spar into the cavity. Molten metal is injected into the die element. The molten metal is solidified within the cavity to cast the hybrid component. The spar establishes an internal structure of the hybrid component. The spar includes a high melting temperature material that defines a first melting temperature greater than a second melting temperature of the molten metal.
    Type: Grant
    Filed: September 29, 2011
    Date of Patent: March 27, 2018
    Assignee: UNITED TECHNOLOGIES CORPORATION
    Inventors: Steven J. Bullied, John Joseph Marcin, Carl R. Verner
  • Publication number: 20180056380
    Abstract: Shot sleeves for high temperature die casting include a nickel-based alloy having a low modulus single crystal with axi-symmetric orientation.
    Type: Application
    Filed: August 26, 2016
    Publication date: March 1, 2018
    Inventors: John Joseph Marcin, Dilip M. Shah, Carl R. Verner, Albert Rabinovich, Weiduo Yu, Thomas N. Slavens
  • Patent number: 9884365
    Abstract: A shot tube includes an inner bore for delivering molten material into a die-cast mold. The shot tube has an outer peripheral surface with at least one surface for receiving a locking member to lock the shot tube into an aperture in a fixed mold portion and an alignment structure for properly aligning the shot tube in the fixed mold portion. An opening receives molten material into the inner bore. A die-cast machine is also disclosed.
    Type: Grant
    Filed: March 6, 2014
    Date of Patent: February 6, 2018
    Assignee: United Technologies Corporation
    Inventors: Mario P. Bochiechio, Yee Ling Kwan, Carl R. Verner