Patents by Inventor Daniel M. Rotter
Daniel M. Rotter 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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Patent number: 11247413Abstract: Composite parts including hybrid plies, methods of forming the composite parts, and systems for forming the composite parts are disclosed herein. The composite parts include a plurality of plies of composite material. At least one ply is a hybrid ply. The hybrid ply is defined by a plurality of distinct ply tiles, and at least one distinct ply tile in the plurality of distinct ply tiles defines at least one ply tile property that differs from a corresponding ply tile property of at least one other distinct ply tile in the plurality of distinct ply tiles. The methods include selecting at least one distinct ply tile and positioning the at least one distinct ply tile. The methods also include selecting at least one other distinct ply tile and positioning the at least one other distinct ply tile. The systems include systems that define the composite parts and/or perform the methods.Type: GrantFiled: December 17, 2018Date of Patent: February 15, 2022Assignee: The Boeing CompanyInventors: Daniel M. Rotter, Bradley Andrew Coxon, Kurtis S. Willden, Stephen Lee Metschan, Paul Chace Wilcoxson, Joseph Jay Pruss, Darrell D. Jones
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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: 11117332Abstract: Composite structure fabrication systems and methods. The systems include a plurality of ply carriers, each of which is configured to support at least one ply segment, and an elongate forming mandrel, which defines an elongate ply forming surface that is shaped to define a surface contour of the composite structure. The systems further include a carrier transfer device, which is configured to selectively convey a selected ply carrier from a ply kitting area to an intermediate location, and a forming machine, which is configured to deform the selected ply carrier and a respective ply segment over a selected portion of the elongate ply forming surface. The forming machine further is configured to separate the selected ply carrier from the respective ply segment and return the selected ply carrier to the carrier transfer device. The methods include methods of operating the systems.Type: GrantFiled: August 12, 2020Date of Patent: September 14, 2021Assignee: The Boeing CompanyInventors: Jose L. Encinosa, Samuel F. Zambrana, Daniel M. Rotter, Michael Robert Chapman, Stephen K. Halladin, Benjamin Bowen Lee, Joshua Dee Little, Douglas Alan McCarville, Jason A. Medenciy, Russell D. Chiupka, Marcin Artur Rabiega, Andrey F. Yurchik, Martin W. Hansen, Thomas P. Harper
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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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Patent number: 10889072Abstract: The present disclosure is directed to a method of making a composite part. The method comprises covering a mold tool for a composite part with a parting film. The method further comprises laying up at least one layer of pre-preg on the parting film covering the mold tool to form a laid-up composite part and removing the laid-up composite part from the parting film. The parting film comprises a polymer sheet having a first major surface and a second major surface; and a first adhesive disposed on the first major surface of the polymer sheet, the first adhesive adhering the polymer sheet to the mold tool.Type: GrantFiled: June 3, 2019Date of Patent: January 12, 2021Assignee: The Boeing CompanyInventors: Hardik Dalal, Alain A. Adjorlolo, Adam F. Gross, Andrew P. Nowak, Brad Andrew Coxon, Kurtis Willden, Daniel M. Rotter, Stephen Lee Metschan, Berryinne Decker
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Publication number: 20200368977Abstract: Composite structure fabrication systems and methods. The systems include a plurality of ply carriers, each of which is configured to support at least one ply segment, and an elongate forming mandrel, which defines an elongate ply forming surface that is shaped to define a surface contour of the composite structure. The systems further include a carrier transfer device, which is configured to selectively convey a selected ply carrier from a ply kitting area to an intermediate location, and a forming machine, which is configured to deform the selected ply carrier and a respective ply segment over a selected portion of the elongate ply forming surface. The forming machine further is configured to separate the selected ply carrier from the respective ply segment and return the selected ply carrier to the carrier transfer device. The methods include methods of operating the systems.Type: ApplicationFiled: August 12, 2020Publication date: November 26, 2020Inventors: Jose L. Encinosa, Samuel F. Zambrana, Daniel M. Rotter, Michael Robert Chapman, Stephen K. Halladin, Benjamin Bowen Lee, Joshua Dee Little, Douglas Alan McCarville, Jason A. Medenciy, Russell D. Chiupka, Marcin Artur Rabiega, Andrey F. Yurchik, Martin W. Hansen, Thomas P. Harper
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Patent number: 10800111Abstract: Composite structure fabrication systems and methods. The systems include a plurality of ply carriers, each of which is configured to support at least one ply segment, and an elongate forming mandrel, which defines an elongate ply forming surface that is shaped to define a surface contour of the composite structure. The systems further include a carrier transfer device, which is configured to selectively convey a selected ply carrier from a ply kitting area to an intermediate location, and a forming machine, which is configured to deform the selected ply carrier and a respective ply segment over a selected portion of the elongate ply forming surface. The forming machine further is configured to separate the selected ply carrier from the respective ply segment and return the selected ply carrier to the carrier transfer device. The methods include methods of operating the systems.Type: GrantFiled: June 16, 2015Date of Patent: October 13, 2020Assignee: The Boeing CompanyInventors: Jose L. Encinosa, Samuel F. Zambrana, Daniel M. Rotter, Michael Robert Chapman, Stephen K. Halladin, Benjamin Bowen Lee, Joshua Dee Little, Douglas Alan McCarville, Jason A. Medenciy, Russell D. Chiupka, Marcin Artur Rabiega, Andrey F. Yurchik, Martin W. Hansen, Thomas P. Harper
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Publication number: 20200189213Abstract: Composite parts including hybrid plies, methods of forming the composite parts, and systems for forming the composite parts are disclosed herein. The composite parts include a plurality of plies of composite material. At least one ply is a hybrid ply. The hybrid ply is defined by a plurality of distinct ply tiles, and at least one distinct ply tile in the plurality of distinct ply tiles defines at least one ply tile property that differs from a corresponding ply tile property of at least one other distinct ply tile in the plurality of distinct ply tiles. The methods include selecting at least one distinct ply tile and positioning the at least one distinct ply tile. The methods also include selecting a least one other distinct ply tile and positioning the at least one other distinct ply tile. The systems include systems that define the composite parts and/or perform the methods.Type: ApplicationFiled: December 17, 2018Publication date: June 18, 2020Inventors: Daniel M. Rotter, Bradley Andrew Coxon, Kurtis S. Willden, Stephen Lee Metschan, Paul Chace Wilcoxson, Joseph Jay Pruss, Darrell D. Jones
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Publication number: 20190283341Abstract: The present disclosure is directed to a method of making a composite part. The method comprises covering a mold tool for a composite part with a parting film. The method further comprises laying up at least one layer of pre-preg on the parting film covering the mold tool to form a layed-up composite part and removing the layed-up composite part from the parting film. The parting film comprises a polymer sheet having a first major surface and a second major surface; and a first adhesive disposed on the first major surface of the polymer sheet, the first adhesive adhering the polymer sheet to the mold tool.Type: ApplicationFiled: June 3, 2019Publication date: September 19, 2019Applicant: The Boeing CompanyInventors: Hardik Dalal, Alain A. Adjorlolo, Adam F. Gross, Andrew P. Nowak, Brad Andrew Coxon, Kurtis Willden, Daniel M. Rotter, Stephen Lee Metschan, Berryinne Decker
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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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Patent number: 10308000Abstract: A method of making a composite part comprises covering a mold tool for a composite part with a parting film, the parting film comprising a polymer sheet and a pressure sensitive adhesive. The parting film is positioned so that the polymer sheet is between the mold tool and the pressure sensitive adhesive. At least one layer of pre-preg is layed up on the parting film covering the mold tool to form a layed-up composite part. The pre-preg comprises an adhesive. The layed-up composite part is removed from the parting film.Type: GrantFiled: May 24, 2016Date of Patent: June 4, 2019Assignee: The Boeing CompanyInventors: Hardik Dalal, Alain A. Adjorlolo, Adam F. Gross, Elena M. Sherman, John J. Vajo, Andrew P. Nowak, Brad Andrew Coxon, Kurtis Willden, Daniel M. Rotter, Stephen Lee Metschan, Berryinne Decker
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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: 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: 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: 10005234Abstract: Devices, systems and methods for compacting a charge of composite material across an edge are disclosed herein. The devices include a vacuum compaction device including a compaction force transfer structure, a sealing structure, and a vacuum distribution manifold. The compaction force transfer structure includes a first barrier structure, a second barrier structure, and a junction support that extends at least partially between the first barrier structure and the second barrier structure. The junction support is configured to maintain the first barrier structure and the second barrier structure at an angle with respect to one another and to permit limited angular motion of the first barrier structure and the second barrier structure relative to one another. The systems include composite structure fabrication systems that include the vacuum compaction device. The methods include methods of operating the vacuum compaction device.Type: GrantFiled: October 29, 2015Date of Patent: June 26, 2018Assignee: The Boeing CompanyInventors: Daniel M. Rotter, Richard V. Phillips, Benjamin J. Stephenson, Stephen Lee Metschan, Scott K. Frankenbery
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Publication number: 20170341357Abstract: A method of making a composite part comprises covering a mold tool for a composite part with a parting film, the parting film comprising a polymer sheet and a pressure sensitive adhesive. The parting film is positioned so that the polymer sheet is between the mold tool and the pressure sensitive adhesive. At least one layer of pre-preg is layed up on the parting film covering the mold tool to form a layed-up composite part. The pre-preg comprises an adhesive. The layed-up composite part is removed from the parting film.Type: ApplicationFiled: May 24, 2016Publication date: November 30, 2017Inventors: Hardik Dalal, Alain A. Adjorlolo, Adam F. Gross, Elena M. Sherman, John J. Vajo, Andrew P. Nowak, Brad Andrew Coxon, Kurtis Willden, Daniel M. Rotter, Stephen Lee Metschan, Berryinne Decker