Patents by Inventor Darrell D. Jones
Darrell D. Jones 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: 20250256471Abstract: An apparatus and system is provided for fabricating composite parts. The system includes subdividing a laminate into zones, laying up tows of fiber reinforced material for the laminate over a layup mandrel via multiple laminations such that each lamination head applies tows in a different zone, and splicing the zones together to form the laminate during the laying up of the tows while moving the layup mandrel in a process direction during fabrication of the composite parts.Type: ApplicationFiled: May 1, 2025Publication date: August 14, 2025Inventors: Daniel R. Smith, Darrell D. Jones, Michael Kenneth-Que Louie, Richard Allen Miller, II, Jordan Seth Erickson
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Patent number: 12350776Abstract: Systems are provided for fabricating a preform for a fuselage section of an aircraft. The system includes advancing a series of arcuate mandrel sections in a process direction through an assembly line, laying up fiber reinforced material onto the arcuate mandrel sections via layup stations, uniting the series of arcuate mandrel sections into a combined mandrel; and splicing the fiber reinforced material laid-up onto the arcuate mandrel sections.Type: GrantFiled: February 20, 2023Date of Patent: July 8, 2025Assignee: The Boeing CompanyInventors: Daniel R. Smith, Darrell D. Jones, Paul T. Pritchard, Jason A. Medenciy, Stephen Keith Kirchmeier, Kurtis Shuldberg Willden, Robert William Whiting, Michael Beerman, Raviendra Sidath Suriyaarachchi, Jeremy Evan Justice, Paul Chace Wilcoxson
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Patent number: 12319398Abstract: Systems and methods are provided for fabricating multiple segment spars for an aircraft. In one example the method includes fabricating preforms of fiber reinforced material for spar segments, hardening the preforms to form the spar segments, and bonding the spar segments together to form a completed spar detail. In addition to bonding, other examples include co-curing and fastening the spar segments. In additional examples, the spar segments include kinks or sub-kinks as described.Type: GrantFiled: November 10, 2021Date of Patent: June 3, 2025Assignee: The Boeing CompanyInventors: Darrell D. Jones, Daniel R. Smith, Carlos Walker, Kurtis Shuldberg Willden, Hiteshkumar M. Patel, Jacob E. Koopmans, Scott Krajca, James P. Dobberfuhl, Marcus C. Hart, Gregory R. Klempel, Steven Kuan-Chi Wu, Justin K. Alfred
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Patent number: 12319015Abstract: Systems and methods are provided for fabricating composite parts. The method includes subdividing a laminate into zones, laying up tows of fiber reinforced material for the laminate over a layup mandrel via multiple laminations such that each lamination head applies tows in a different zone, and splicing the zones together to form the laminate during the laying up of the tows while moving the layup mandrel in a process direction during fabrication of the composite parts.Type: GrantFiled: November 10, 2021Date of Patent: June 3, 2025Assignee: The Boeing CompanyInventors: Daniel R. Smith, Darrell D. Jones, Michael Kenneth-Que Louie, Richard Allen Miller, II, Jordan Seth Erickson
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Patent number: 12296984Abstract: Systems and methods are provided for assembling a wing. Methods include suspending an upper wing panel of an aircraft beneath a shuttle, translating a rib to a position it, and placing the rib into contact with, then affixing the rib to, the upper wing panel, while suspended. Some methods include installing ribs and spars to the upper wing panel, and joining a lower wing panel to the ribs and spars, while the upper wing panel is suspended. Some methods involve joining ribs to spars (e.g., all, or some) to produce a support structure that is then affixed to the upper wing panel. Systems include a shuttle that suspends an upper wing panel, and a cart that includes supports to hold a rib, a chassis to translate the rib to a position beneath the upper wing panel, and a lifting apparatus to lift the rib into contact with the upper wing panel.Type: GrantFiled: December 19, 2023Date of Patent: May 13, 2025Assignee: The Boeing CompanyInventors: Daniel R. Smith, Darrell D. Jones
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Patent number: 12259362Abstract: Systems and methods are provided for inspecting aircraft fuselages. Non-Destructive Inspection (NDI) stations inspect sections of a fuselage via pulsed-line assembly techniques. After each pulse, a section of fuselage is moved by less than its length, and one or more NDI stations disposed at different portions of the section to inspect the section of fuselage for out-of-tolerance conditions. A method for inspecting a structure for inconsistencies which includes advancing a structure along a track in a process direction through a Non-Destructive Inspection (NDI) station, indexing the structure to the NDI station and inspecting the structure with the NDI station.Type: GrantFiled: November 10, 2021Date of Patent: March 25, 2025Assignee: The Boeing CompanyInventors: Daniel R. Smith, Darrell D. Jones, Barry A. Fetzer, Jeremy Evan Justice, James C. Kennedy
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Patent number: 12252271Abstract: Systems and methods are provided for assembling an aircraft. The method includes receiving an upper half barrel section of fuselage that is in a crown up orientation and installing a crown module into the upper half barrel section.Type: GrantFiled: November 10, 2021Date of Patent: March 18, 2025Assignee: The Boeing CompanyInventors: Daniel R. Smith, Darrell D. Jones, Jeremy Evan Justice
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Patent number: 12246852Abstract: Systems and methods are provided for assembling aircraft fuselages. One embodiment is a method for assembling a fuselage of an aircraft. The method includes indexing an arcuate section of a fuselage to a frame installation station, feeding a frame at the frame installation station into a concavity defined by the arcuate section, placing the frame against an Inner Mold Line (IML) of the arcuate section while the frame is within the concavity, and affixing the frame to the arcuate section.Type: GrantFiled: November 10, 2021Date of Patent: March 11, 2025Assignee: The Boeing CompanyInventors: Daniel R. Smith, Darrell D. Jones, Farahnaz Sisco, Kwok Tung Chan, Riley HansonSmith
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Publication number: 20250058489Abstract: Apparatus and methods are provided for fabrication of a structure, for example, a half barrel section of a fuselage. The apparatus includes an indexing unit dimensioned for coupling to an indexing feature disposed on the structure. The structure proceeds along a process direction during fabrication. A cutting station cuts out manufacturing excess from the structure to form, for example, openings for windows and doors. A method for fabrication of a structure includes indexing a structure to a cutting station based on an indexing feature associated or located on the structure. The method includes operating the cutting station to cut manufacturing excess from the structure. A method includes removing cut sections of the manufacturing excess and routing these sections away from the cutting station.Type: ApplicationFiled: November 4, 2024Publication date: February 20, 2025Inventors: Daniel R. Smith, Darrell D. Jones, Monte D. Wright
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Patent number: 12202164Abstract: Systems and methods are provided for inspecting a structure. One embodiment is a method for inspecting a structure. The method includes advancing a structure along a track in a process direction, aligning a Non-Destructive Inspection (NDI) station at the track with an edge of the structure that was trimmed upstream of the cleaning station, imaging the edge via the Non-Destructive Inspection (NDI) station, characterizing the edge based on the imaging, and advancing the structure further in the process direction via the track.Type: GrantFiled: November 10, 2021Date of Patent: January 21, 2025Assignee: The Boeing CompanyInventors: Darrell D. Jones, Daniel R. Smith
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Patent number: 12194651Abstract: Apparatus and methods are provided for fabrication of a structure, for example, a half barrel section of a fuselage. The apparatus includes an indexing unit dimensioned for coupling to an indexing feature disposed on the structure. The structure proceeds along a process direction during fabrication. A cutting station cuts out manufacturing excess from the structure to form, for example, openings for windows and doors. A method for fabrication of a structure includes indexing a structure to a cutting station based on an indexing feature associated or located on the structure. The method includes operating the cutting station to cut manufacturing excess from the structure. A method includes removing cut sections of the manufacturing excess and routing these sections away from the cutting station.Type: GrantFiled: November 10, 2021Date of Patent: January 14, 2025Assignee: The Boeing CompanyInventors: Daniel R. Smith, Darrell D. Jones, Monte D. Wright
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Patent number: 12187457Abstract: Systems and methods are provided for installing ribs and/or spars to a wing panel while a contour is enforced. Methods include suspending a wing panel beneath a shuttle that enforces the contour, advancing the wing panel through work stations via the shuttle, and installing a rib or a spar (or another wing panel) at a work station, while the contour is enforced. Other methods include locating a wing panel beneath a shuttle, coupling adjustable-length pogos to the wing panel at locations distinct from those corresponding with an installation location, e.g. for a rib or a spar, and controlling the length of the pogos to enforce a contour to the wing panel. Some systems include a track, work stations disposed along the track, and a shuttle to advance along the track and convey a wing panel to each of the work stations while enforcing a contour onto the wing panel.Type: GrantFiled: January 24, 2024Date of Patent: January 7, 2025Assignee: The Boeing CompanyInventors: Daniel R. Smith, Darrell D. Jones
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Patent number: 12077319Abstract: Systems and methods are provided for fabricating a part on a mandrel. The system includes a series of stations divided into at least two groups of stations, wherein each group of stations performs fabrication operations on a particular zone of the mandrel.Type: GrantFiled: November 10, 2021Date of Patent: September 3, 2024Assignee: The Boeing CompanyInventors: Daniel R. Smith, Darrell D. Jones, Paul Chace Wilcoxson, Raviendra Sidath Suriyaarachchi, Robert William Whiting, Jeremy Evan Justice
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Patent number: 12049330Abstract: Systems and methods are provided for assembling an aircraft. The method includes receiving a lower half barrel section of fuselage that is inverted to a keel-up orientation; and installing a floor grid into the lower half barrel section while inverted.Type: GrantFiled: November 10, 2021Date of Patent: July 30, 2024Assignee: The Boeing CompanyInventors: Daniel R. Smith, Darrell D. Jones, Jeremy Evan Justice
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Publication number: 20240166372Abstract: Systems and methods are provided for assembling a section of a fuselage of an aircraft. The method includes pulsing a half barrel section of the fuselage along a track in a process direction, utilizing an indexing feature associated with the half barrel section to determine a desired contour for a portion of the half barrel section, and enforcing the desired contour onto the half barrel section using components that enforce an inner mold line and components that enforce an outer mold line when the half barrel section is out of tolerance from the desired contour.Type: ApplicationFiled: January 29, 2024Publication date: May 23, 2024Inventors: Daniel R. Smith, Darrell D. Jones
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Publication number: 20240158098Abstract: Systems and methods are provided for installing ribs and/or spars to a wing panel while a contour is enforced. Methods include suspending a wing panel beneath a shuttle that enforces the contour, advancing the wing panel through work stations via the shuttle, and installing a rib or a spar (or another wing panel) at a work station, while the contour is enforced. Other methods include locating a wing panel beneath a shuttle, coupling adjustable-length pogos to the wing panel at locations distinct from those corresponding with an installation location, e.g. for a rib or a spar, and controlling the length of the pogos to enforce a contour to the wing panel. Some systems include a track, work stations disposed along the track, and a shuttle to advance along the track and convey a wing panel to each of the work stations while enforcing a contour onto the wing panel.Type: ApplicationFiled: January 24, 2024Publication date: May 16, 2024Inventors: Daniel R. Smith, Darrell D. Jones
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Publication number: 20240158099Abstract: Systems and methods are provided for assembling a wing. Methods include suspending an upper wing panel of an aircraft beneath a shuttle, translating a rib to a position it, and placing the rib into contact with, then affixing the rib to, the upper wing panel, while suspended. Some methods include installing ribs and spars to the upper wing panel, and joining a lower wing panel to the ribs and spars, while the upper wing panel is suspended. Some methods involve joining ribs to spars (e.g., all, or some) to produce a support structure that is then affixed to the upper wing panel. Systems include a shuttle that suspends an upper wing panel, and a cart that includes supports to hold a rib, a chassis to translate the rib to a position beneath the upper wing panel, and a lifting apparatus to lift the rib into contact with the upper wing panel.Type: ApplicationFiled: December 19, 2023Publication date: May 16, 2024Inventors: Daniel R. Smith, Darrell D. Jones
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Publication number: 20240158097Abstract: Systems and methods are provided for assembling a structure. The systems and method including micro pulsing a structure along a track in a process direction by less than a length of the structure. The structure is indexed to one or more work stations by mating indexing features in a manufacturing excess of the structure to complementary features at the work stations. The work stations would the perform work on the structure at the work stations while the structure is indexed to the work stations. Iteratively repeating the micro pulsing and indexing and working upon the structure until it is ready to advance to the next assembly process.Type: ApplicationFiled: January 19, 2024Publication date: May 16, 2024Inventors: Daniel R. Smith, Darrell D. Jones, Frederick M. Swanstrom
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Patent number: 11926435Abstract: Systems and methods are provided for assembling a structure. The systems and method including micro pulsing a structure along a track in a process direction by less than a length of the structure. The structure is indexed to one or more work stations by mating indexing features in a manufacturing excess of the structure to complementary features at the work stations. The work stations would the perform work on the structure at the work stations while the structure is indexed to the work stations. Iteratively repeating the micro pulsing and indexing and working upon the structure until it is ready to advance to the next assembly process.Type: GrantFiled: November 10, 2021Date of Patent: March 12, 2024Assignee: The Boeing CompanyInventors: Daniel R. Smith, Darrell D. Jones, Frederick M. Swanstrom
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Patent number: 11919661Abstract: Systems and methods are provided for installing ribs and/or spars to a wing panel while a contour is enforced. Methods include suspending a wing panel beneath a shuttle that enforces the contour, advancing the wing panel through work stations via the shuttle, and installing a rib or a spar (or another wing panel) at a work station, while the contour is enforced. Other methods include locating a wing panel beneath a shuttle, coupling adjustable-length pogos to the wing panel at locations distinct from those corresponding with an installation location, e.g. for a rib or a spar, and controlling the length of the pogos to enforce a contour to the wing panel. Some systems include a track, work stations disposed along the track, and a shuttle to advance along the track and convey a wing panel to each of the work stations while enforcing a contour onto the wing panel.Type: GrantFiled: November 10, 2021Date of Patent: March 5, 2024Assignee: The Boeing CompanyInventors: Daniel R. Smith, Darrell D. Jones