Patents by Inventor Darren K. Rogers
Darren K. Rogers 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: 9835035Abstract: A method is provided for making a mold for casting advanced turbine airfoils (e.g. gas turbine blade and vane castings) which can include complex internal and external air cooling features to improve efficiency of airfoil cooling during operation in the gas turbine hot gas stream. The method steps involve incorporating at least one fugitive insert in a ceramic material in a manner to form a core and at least a portion of an integral, cooperating mold wall wherein the core defines an internal cooling feature to be imparted to the cast airfoil and the at least portion of the mold wall has an inner surface that defines an external cooling feature to be imparted to the cast airfoil, selectively removing the fugitive insert, and incorporating the core and the at least portion of the integral, cooperating mold wall in a mold for receiving molten metal or alloy cast in the mold.Type: GrantFiled: March 12, 2013Date of Patent: December 5, 2017Assignee: Howmet CorporationInventors: Boyd A. Mueller, Michael A. Pepper, Darren K. Rogers, Gail R. Cole
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Patent number: 8997836Abstract: A multi-wall ceramic core for casting an airfoil with one or more internal cooling passages is made by preforming at least one fugitive core insert to have a joint-forming surface with a male and/or female joint feature and then forming at least one fugitive core insert in-situ adjacent and integrally connected and fused to the at least one preformed core insert at the joint-forming surface to form an interlocked, fused joint to form a composite core insert that includes features to form internal passage surfaces in the core when the composite core insert is removed. Another aspect involves preforming first and second fugitive core inserts to have respective joint-forming surfaces with respective snap-fittable joint features and assembling the first and second fugitive core inserts to form a composite core insert by snap fitting the snap-fittable joint features together to form an interlocked joint.Type: GrantFiled: October 21, 2014Date of Patent: April 7, 2015Assignee: Howmet CorporationInventors: Boyd A. Mueller, Darren K. Rogers, Timothy J. Molamphy
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Publication number: 20150053365Abstract: A multi-wall ceramic core for casting an airfoil with one or more internal cooling passages is made by preforming at least one fugitive core insert to have a joint-forming surface with a male and/or female joint feature and then forming at least one fugitive core insert in-situ adjacent and integrally connected and fused to the at least one preformed core insert at the joint-forming surface to form an interlocked, fused joint to form a composite core insert that includes features to form internal passage surfaces in the core when the composite core insert is removed. Another aspect involves preforming first and second fugitive core inserts to have respective joint-forming surfaces with respective snap-fittable joint features and assembling the first and second fugitive core inserts to form a composite core insert by snap fitting the snap-fittable joint features together to form an interlocked joint.Type: ApplicationFiled: October 21, 2014Publication date: February 26, 2015Inventors: Boyd A. Mueller, Darren K. Rogers, Timothy J. Molamphy
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Patent number: 8915289Abstract: A multi-wall ceramic core for casting an airfoil with one or more internal cooling passages is made by preforming at least one fugitive core insert to have a joint-forming surface with a male and/or female joint feature and then forming at least one fugitive core insert in-situ adjacent and integrally connected and fused to the at least one preformed core insert at the joint-forming surface to form an interlocked, fused joint to form a composite core insert that includes features to form internal passage surfaces in the core when the composite core insert is removed. Another aspect involves preforming first and second fugitive core inserts to have respective joint-forming surfaces with respective snap-fittable joint features and assembling the first and second fugitive core inserts to form a composite core insert by snap fitting the snap-fittable joint features together to form an interlocked joint.Type: GrantFiled: March 13, 2013Date of Patent: December 23, 2014Assignee: Howmet CorporationInventors: Boyd A. Mueller, Darren K. Rogers, Timothy J. Molamphy
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Publication number: 20130220571Abstract: A multi-wall ceramic core for casting an airfoil with one or more internal cooling passages is made by preforming at least one fugitive core insert to have a joint-forming surface with a male and/or female joint feature and then forming at least one fugitive core insert in-situ adjacent and integrally connected and fused to the at least one preformed core insert at the joint-forming surface to form an interlocked, fused joint to form a composite core insert that includes features to form internal passage surfaces in the core when the composite core insert is removed. Another aspect involves preforming first and second fugitive core inserts to have respective joint-forming surfaces with respective snap-fittable joint features and assembling the first and second fugitive core inserts to form a composite core insert by snap fitting the snap-fittable joint features together to form an interlocked joint.Type: ApplicationFiled: March 13, 2013Publication date: August 29, 2013Applicant: Howment CorporationInventors: Boyd A. Mueller, Darren K. Rogers, Timothy J. Molamphy
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Patent number: 8048528Abstract: According to the present invention there is provided coal-based cellular or porous products, also referred to herein as “carbon foams”, having a density of preferably between about 0.1 g/cm3 and about 0.8 g/cm3 and most preferably between about 0.3 and about 0.4 g/cm3 that are produced by the controlled heating of coal particulate preferably up to ¼ inch in diameter in a “mold” and under a non-oxidizing atmosphere. The coal-based cellular or porous products of the present invention have ash contents typically greater than about 1%. More typically these coal-based cellular or porous products have ash contents greater than about 3%, with ash contents in the range of about 7% to 15% being most typical. The ash residue remaining after essentially complete combustion/oxidation of these coal-based cellular or porous products is predominately composed of oxides of aluminum and silicon. Additionally, the cellular coal-based products of the present invention have relatively low overall B.E.T. surface areas.Type: GrantFiled: June 2, 2005Date of Patent: November 1, 2011Assignee: Touchstone Research Laboratory, Ltd.Inventors: Thomas M. Matviya, Darren K. Rogers
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Patent number: 7435494Abstract: Coal based carbon foams that are produced by the controlled heating of coal particulate in a mold and under a non-oxidizing atmosphere and subsequently graphitized have been found to provide excellent electrode materials for electrochemical cell applications.Type: GrantFiled: January 10, 2005Date of Patent: October 14, 2008Assignee: Touchstone Research Laboratory, Ltd.Inventors: Darren K. Rogers, Janusz Wladyslaw Plucinski
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Patent number: 6899970Abstract: Coal based carbon foams that are produced by the controlled beating of coal particulate in a mold and under a non-oxidizing atmosphere and subsequently graphitized have been found to provide excellent electrode materials for electrochemical cell applications.Type: GrantFiled: June 25, 2001Date of Patent: May 31, 2005Assignee: Touchstone Research Laboratory, Ltd.Inventors: Darren K. Rogers, Janusz Wladyslaw Plucinski