Patents by Inventor Darren Lee Hallman

Darren Lee Hallman 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).

  • Patent number: 10832753
    Abstract: A unit cell structure is provided. The unit cell structure includes a first section and a second section. The first section defines a first load path and includes a first plurality of first unit cells joined together. The second section defines a second load path separate from the first load path and includes a second plurality of second unit cells joined together, each second unit cell of the second plurality of second unit cells nested within and spaced apart from each first unit cell of the first plurality of first unit cells of the first section.
    Type: Grant
    Filed: July 31, 2017
    Date of Patent: November 10, 2020
    Assignee: General Electric Company
    Inventors: Ananda Barua, Arun Karthi Subramaniyan, Changjie Sun, Daniel Jason Erno, Darren Lee Hallman
  • Patent number: 10711877
    Abstract: A gearbox assembly for a gas turbine engine used in an aircraft having passive lubrication capabilities during wind milling includes a gearbox housing, a gear train assembly housed within the gearbox housing, a lubricant in the gearbox housing for lubricating the gear train assembly, and a first scavenge port formed in the gearbox housing. The first scavenge port is changeable between an open position and a closed position. Further, the first scavenge port remains in the open position during normal operation of the gas turbine engine to allow the lubricant to drain from the gearbox housing. Upon occurrence of a loss of lubricant pressure in the gearbox assembly, the first scavenge port is changed to the closed position to trap at least a portion of the lubricant in the gearbox housing. Thus, the trapped lubricant provides passive lubrication to the gear train assembly during the loss of lubricant pressure.
    Type: Grant
    Filed: February 23, 2018
    Date of Patent: July 14, 2020
    Assignee: General Electric Company
    Inventors: Kenneth Lee Fisher, George Hanna Ghanime, Bugra Han Ertas, Darren Lee Hallman
  • Patent number: 10661552
    Abstract: A controller for use in an additive manufacturing system including a consolidation device configured to consolidate material is provided. The controller is configured to receive a build file for a component including a plurality of build layers, wherein each build layer includes a component outer perimeter, at least one build layer generating function, at least one generating function variable, and at least one generating function constant. The controller is configured to generate at least one control signal to control a power output throughout at least one scan path of the consolidation device across the material for each build layer of the plurality of build layers, the at least one scan path generated based at least partially on the component outer perimeter, the at least one generating function, the at least one generating function variable, and the at least one generating function constant for each build layer.
    Type: Grant
    Filed: July 28, 2017
    Date of Patent: May 26, 2020
    Assignee: General Electric Company
    Inventors: Ananda Barua, Arun Karthi Subramaniyan, Daniel Jason Erno, Darren Lee Hallman
  • Patent number: 10641332
    Abstract: A bearing includes an inner ring having an outer surface and a cage having both an inner surface and an outer surface. The cage inner surface is positioned to be in opposition to the inner ring outer surface. The bearing further includes an outer ring having both an inner surface and an outer surface. The outer ring inner surface is positioned to be in opposition to the cage outer surface. One or more of the inner ring outer surface, the cage inner surface, the cage outer surface, and the outer ring inner surface defines a non-circular circumferential profile.
    Type: Grant
    Filed: December 6, 2016
    Date of Patent: May 5, 2020
    Assignee: General Electric Company
    Inventors: Fabio Nonato de Paula, Bugra Han Ertas, Darren Lee Hallman
  • Patent number: 10508731
    Abstract: A planet gear includes a pin and an annular planet gear rim. The pin has a pin radius. The pin includes a pin outer surface. The annular planet gear rim has an inner radius and an outer radius. The annular planet gear rim includes an inner surface and an outer surface. The inner surface and the pin outer surface define a clearance therebetween. The clearance is greater than 0 when a radial force is applied to the planet gear.
    Type: Grant
    Filed: January 5, 2017
    Date of Patent: December 17, 2019
    Assignee: General Electric Company
    Inventors: Darren Lee Hallman, Donald Albert Bradley, Changjie Sun, Bugra Han Ertas
  • Publication number: 20190311758
    Abstract: A unit cell structure is provided. The unit cell structure includes a first section and a second section. The first section defines a first load path and includes a first plurality of first unit cells joined together. The second section defines a second load path separate from the first load path and includes a second plurality of second unit cells joined together, each second unit cell of the second plurality of second unit cells nested within and spaced apart from each first unit cell of the first plurality of first unit cells of the first section.
    Type: Application
    Filed: July 31, 2017
    Publication date: October 10, 2019
    Inventors: Ananda Barua, Arun Karthi Subramaniyan, Changjie Sun, Daniel Jason Erno, Darren Lee Hallman
  • Patent number: 10408304
    Abstract: A gear having an axis of rotation includes a gear rim, with at least a portion of the gear rim configured to receive a load and define a loaded gear rim arc corresponding to the portion of the gear rim. A bearing pin extends axially through the gear rim, the gear rim and the bearing pin defining a roller element gap therebetween. The gear rim is configured to define a loaded roller element gap arc substantially concentric with the loaded gear rim arc, the loaded element gap arc having a loaded roller element gap arc length. The gear rim is further configured to retain a loaded bearing portion of the bearing within the portion of the roller element gap such that a loaded bearing portion length is in a range from and including about 75% to and including about 125% of the loaded roller element gap arc length.
    Type: Grant
    Filed: February 7, 2017
    Date of Patent: September 10, 2019
    Assignee: General Electric Company
    Inventor: Darren Lee Hallman
  • Patent number: 10400678
    Abstract: A gear includes a first gear rim, a second gear rim, and an axial groove. The first gear rim has a first gear rim rotational stiffness and includes a plurality of first gear teeth. The second gear rim has a second gear rim rotational stiffness. The second gear rim includes a plurality of second gear teeth complementing the plurality of first gear teeth defining a plurality of complementary first gear teeth and a plurality of complementary second gear teeth. The axial groove extends between the first gear rim and the second gear rim. The axial groove has an axial groove rotational stiffness that less than at least one of the first gear rim rotational stiffness and the second gear rim rotational stiffness.
    Type: Grant
    Filed: January 3, 2017
    Date of Patent: September 3, 2019
    Assignee: General Electric Company
    Inventors: Darren Lee Hallman, Kenneth Lee Fisher
  • Publication number: 20190264800
    Abstract: A gearbox assembly for a gas turbine engine used in an aircraft having passive lubrication capabilities during wind milling includes a gearbox housing, a gear train assembly housed within the gearbox housing, a lubricant in the gearbox housing for lubricating the gear train assembly, and a first scavenge port formed in the gearbox housing. The first scavenge port is changeable between an open position and a closed position. Further, the first scavenge port remains in the open position during normal operation of the gas turbine engine to allow the lubricant to drain from the gearbox housing. Upon occurrence of a loss of lubricant pressure in the gearbox assembly, the first scavenge port is changed to the closed position to trap at least a portion of the lubricant in the gearbox housing. Thus, the trapped lubricant provides passive lubrication to the gear train assembly during the loss of lubricant pressure.
    Type: Application
    Filed: February 23, 2018
    Publication date: August 29, 2019
    Inventors: Kenneth Lee Fisher, George Hanna Ghanime, Bugra Han Ertas, Darren Lee Hallman
  • Publication number: 20190186598
    Abstract: A planet gear includes an annular planet gear rim having a constant inner radius along a complete axial length and an outer radius defined as the radial distance to the root of the gear teeth. The annular planet gear rim further has an average rim radius defined at a halfway point between the constant inner radius and the outer radius. The average rim radius and the rim thickness define a ratio including values in a range from and including about 4 to and including about 9. A gear assembly and turbomachine including the planet gear are disclosed.
    Type: Application
    Filed: February 25, 2019
    Publication date: June 20, 2019
    Inventors: Kennneth Lee Fisher, Darren Lee Hallman, Bugra Han Ertas, Donald Albert Bradley, Haris Ligata, William Howard Hasting, Ning Fang, Gert Johannes van der Merwe, Mark Alan Rhoads
  • Patent number: 10247298
    Abstract: A bearing pin assembly includes a bearing pin including a substantially rigid pin body. The bearing pin assembly also includes a resilient section disposed about the substantially rigid pin body. The resilient section is configured to facilitate bending of the bearing pin during operational loading of the bearing pin.
    Type: Grant
    Filed: January 10, 2017
    Date of Patent: April 2, 2019
    Assignee: GENERAL ELECTRIC COMPANY
    Inventor: Darren Lee Hallman
  • Patent number: 10247297
    Abstract: A gearbox includes a gearbox housing, at least one gear, and a plurality of scavenge ports. The gearbox housing has a top portion, two horizontal portions, and a bottom portion opposite the top portion. The bottom portion is oriented in the direction a fluid would drain under the influence of gravity during normal operations. The two horizontal portions are oriented at a right angle relative to the bottom portion. The at least one gear is disposed within the gearbox housing and has a first axial position. The plurality of scavenge ports are defined by the gearbox housing. The plurality of scavenge ports are aligned axially with the at least one gear at the first axial position. At least one scavenge port of the plurality of scavenge ports is located within the gearbox housing at the two horizontal portions.
    Type: Grant
    Filed: January 18, 2017
    Date of Patent: April 2, 2019
    Assignee: GENERAL ELECTRIC COMPANY
    Inventors: Darren Lee Hallman, Joseph Robert Dickman
  • Patent number: 10228024
    Abstract: A method of designing and manufacturing a bearing pin having an external bearing pin geometry includes generating a first pin model conforming to the external bearing pin geometry. One or more operational loads to be applied to the bearing pin are then simulated on the first pin model to identifying at least one first internal region of the first pin model in which at least one of stress, strain, and displacement are below a first predetermined limit. The method further includes generating a final pin model based on the first pin model by forming a first void by removing the at least one first internal region from the first pin model. The bearing pin is then manufactured in accordance with the final pin model.
    Type: Grant
    Filed: January 10, 2017
    Date of Patent: March 12, 2019
    Assignee: General Electric Company
    Inventor: Darren Lee Hallman
  • Publication number: 20190030878
    Abstract: A controller for use in an additive manufacturing system including a consolidation device configured to consolidate material is provided. The controller is configured to receive a build file for a component including a plurality of build layers, wherein each build layer includes a component outer perimeter, at least one build layer generating function, at least one generating function variable, and at least one generating function constant. The controller is configured to generate at least one control signal to control a power output throughout at least one scan path of the consolidation device across the material for each build layer of the plurality of build layers, the at least one scan path generated based at least partially on the component outer perimeter, the at least one generating function, the at least one generating function variable, and the at least one generating function constant for each build layer.
    Type: Application
    Filed: July 28, 2017
    Publication date: January 31, 2019
    Inventors: Ananda Barua, Arun Karthi Subramaniyan, Daniel Jason Erno, Darren Lee Hallman
  • Publication number: 20180320758
    Abstract: A gear having an axis of rotation includes a gear rim, with at least a portion of the gear rim configured to receive a load and define a loaded gear rim arc corresponding to the portion of the gear rim. A bearing pin extends axially through the gear rim, the gear rim and the bearing pin defining a roller element gap therebetween. The gear rim is configured to define a loaded roller element gap arc substantially concentric with the loaded gear rim arc, the loaded element gap arc having a loaded roller element gap arc length. The gear rim is further configured to retain a loaded bearing portion of the bearing within the portion of the roller element gap such that a loaded bearing portion length is in a range from and including about 75% to and including about 125% of the loaded roller element gap arc length.
    Type: Application
    Filed: February 7, 2017
    Publication date: November 8, 2018
    Inventor: Darren Lee Hallman
  • Publication number: 20180202536
    Abstract: A gearbox includes a gearbox housing, at least one gear, and a plurality of scavenge ports. The gearbox housing has a top portion, two horizontal portions, and a bottom portion opposite the top portion. The bottom portion is oriented in the direction a fluid would drain under the influence of gravity during normal operations. The two horizontal portions are oriented at a right angle relative to the bottom portion. The at least one gear is disposed within the gearbox housing and has a first axial position. The plurality of scavenge ports are defined by the gearbox housing. The plurality of scavenge ports are aligned axially with the at least one gear at the first axial position. At least one scavenge port of the plurality of scavenge ports is located within the gearbox housing at the two horizontal portions.
    Type: Application
    Filed: January 18, 2017
    Publication date: July 19, 2018
    Inventors: Darren Lee Hallman, Joseph Robert Dickman
  • Publication number: 20180195559
    Abstract: A method of designing and manufacturing a bearing pin having an external bearing pin geometry includes generating a first pin model conforming to the external bearing pin geometry. One or more operational loads to be applied to the bearing pin are then simulated on the first pin model to identifying at least one first internal region of the first pin model in which at least one of stress, strain, and displacement are below a first predetermined limit. The method further includes generating a final pin model based on the first pin model by forming a first void by removing the at least one first internal region from the first pin model. The bearing pin is then manufactured in accordance with the final pin model.
    Type: Application
    Filed: January 10, 2017
    Publication date: July 12, 2018
    Inventor: Darren Lee Hallman
  • Publication number: 20180195601
    Abstract: A bearing pin assembly includes a bearing pin including a substantially rigid pin body. The bearing pin assembly also includes a resilient section disposed about the substantially rigid pin body. The resilient section is configured to facilitate bending of the bearing pin during operational loading of the bearing pin.
    Type: Application
    Filed: January 10, 2017
    Publication date: July 12, 2018
    Inventor: Darren Lee Hallman
  • Publication number: 20180187773
    Abstract: A planet gear includes a pin and an annular planet gear rim. The pin has a pin radius. The pin includes a pin outer surface. The annular planet gear rim has an inner radius and an outer radius. The annular planet gear rim includes an inner surface and an outer surface. The inner surface and the pin outer surface define a clearance therebetween. The clearance is greater than 0 when a radial force is applied to the planet gear.
    Type: Application
    Filed: January 5, 2017
    Publication date: July 5, 2018
    Inventors: Darren Lee Hallman, Donald Albert Bradley, Changjie Sun, Bugra Han Ertas
  • Publication number: 20180187753
    Abstract: A gear includes a first gear rim, a second gear rim, and an axial groove. The first gear rim has a first gear rim rotational stiffness and includes a plurality of first gear teeth. The second gear rim has a second gear rim rotational stiffness. The second gear rim includes a plurality of second gear teeth complementing the plurality of first gear teeth defining a plurality of complementary first gear teeth and a plurality of complementary second gear teeth. The axial groove extends between the first gear rim and the second gear rim. The axial groove has an axial groove rotational stiffness that less than at least one of the first gear rim rotational stiffness and the second gear rim rotational stiffness.
    Type: Application
    Filed: January 3, 2017
    Publication date: July 5, 2018
    Inventors: Darren Lee Hallman, Kenneth Lee Fisher