Patents by Inventor Darryl Mark Toni
Darryl Mark Toni 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: 20190186184Abstract: A pin of a hinge system movable between a first position and a second position is provided, wherein in the first position, the pin is received within a first component and a second component. The pin includes a cylindrical body coupled to an actuator for movement along an axis between the first position and the second position. A tip is removably attached to an end of the cylindrical body. The tip is configured to contact at least one of the first component and the second component when the pin is in the first position.Type: ApplicationFiled: February 11, 2019Publication date: June 20, 2019Inventors: Jonathan Bremmer, Darryl Mark Toni, David J. Goldschmidt, James S. Giampapa, Jeffrey G. Sauer
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Publication number: 20180208330Abstract: A structural reinforcement member is provided to be affixable to a metallic member. The metallic member defines a stress concentration section at which the metallic member is subject to loading in at least one direction such that stress is generated at the stress concentration section in at least one corresponding principal stress direction. The structural reinforcement member includes a polymer matrix composite (PMC) patch element and a bondline. The PMC patch element includes fibers suspended within a polymer matrix. The bondline is disposed to affix the PMC patch element to a surface of the metallic member at the stress concentration section such that the fibers extend along the principal stress direction.Type: ApplicationFiled: July 13, 2016Publication date: July 26, 2018Inventors: Wenping Zhao, Jr., Zaffir A. Chaudhry, Darryl Mark Toni, Peter Kummer
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Publication number: 20180094467Abstract: A pin of a hinge system movable between a first position and a second position is provided, wherein in the first position, the pin is received within a first component and a second component. The pin includes a cylindrical body coupled to an actuator for movement along an axis between the first position and the second position. A tip is removably attached to an end of the cylindrical body. The tip is configured to contact at least one of the first component and the second component when the pin is in the first position.Type: ApplicationFiled: December 11, 2015Publication date: April 5, 2018Inventors: Jonathan Bremmer, Darryl Mark Toni, David J. Goldschmidt, James S. Giampapa, Jeffrey G. Sauer
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Publication number: 20180065277Abstract: A method of manufacturing a fabricated part having complex geometry is provided. The method includes generating a digital model of a tooling having a complex geometry; additively manufacturing a tooling based on the digital model from tooling material; laying-up fabrication materials on the tooling; curing the fabrication materials on the tooling to form a fabricated part; and removing the tooling from the fabricated part.Type: ApplicationFiled: January 22, 2016Publication date: March 8, 2018Inventors: Jonathan Bremmer, Darryl Mark Toni, Jeffrey G. Sauer, Robert A. Lacko, Juan J. Prieto, JR., Christopher John Foti
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Patent number: 9539769Abstract: A composite structure includes a first laminate, a second laminate, and at least one core component located between the first laminate and the second laminate. The at least one core component includes a honeycomb core and at least one locking ply extending from the honeycomb core between the first laminate and the second laminate. The at least one locking ply is configured such that a pressure applied during a cure cycle of the composite structure retains the at least one locking ply between the first laminate and the second laminate thereby preventing movement of core component.Type: GrantFiled: October 17, 2011Date of Patent: January 10, 2017Assignee: SIKORSKY AIRCRAFT CORPORATIONInventors: Jonathan Bremmer, Jeffrey G. Sauer, Edward Joseph Fabian, Paul H. Denavit, Darryl Mark Toni, William E. Hovan, III
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Publication number: 20160375668Abstract: A method of forming a sandwich composite structure by placing a core under a compressive force or a tensile force and applying a first layer to a first surface of the core. The core and first layer are then heated. The compressive or tensile force is then released, allowing the composite structure to take shape.Type: ApplicationFiled: May 5, 2015Publication date: December 29, 2016Inventors: Jonathan Bremmer, Robert A. Lacko, Jeffrey G. Sauer, Darryl Mark Toni
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Patent number: 9427940Abstract: A composite panel includes a support layer including a first plurality of prepreg plies wrapped around at least one mandrel; a mid-plane impact layer including a second plurality of prepreg plies, the mid-plane impact layer adjacent to the support layer; a upper skin layer including a third plurality of prepreg plies, the upper skin layer adjacent to the mid-place impact layer; and a lower skin layer including a fourth plurality of prepreg plies, the lower skin layer adjacent to the support layer; whereby each of the first, second, third, and fourth plurality of prepreg plies are co-cured to form the composite panel.Type: GrantFiled: November 12, 2013Date of Patent: August 30, 2016Assignee: SIKORSKY AIRCRAFT CORPORATIONInventors: Jonathan Bremmer, Darryl Mark Toni, William E. Hovan, III, Allan R. Macallister, Jr., Jeffrey G. Sauer, Christian A. Rogg, Robert A. Lacko, David M. Lent, Andrew Varga
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Patent number: 9409358Abstract: A composite structure includes a first laminate and a second laminate. At least one core assembly is located between the first laminate and the second laminate. The at least one core assembly includes a core component and a layer of filler material disposed at a first face of the core component. The layer of filler material at least partially fills selected cells of the core component to a fill depth such that the filler material rigidizes when cured to prevent movement and/or crushing of core component under a pressure applied during a cure cycle of the composite structure.Type: GrantFiled: October 15, 2012Date of Patent: August 9, 2016Assignee: SIKORSKY AIRCRAFT CORPORATIONInventors: Jonathan Bremmer, Darryl Mark Toni, Jeffrey G. Sauer, Edward Joseph Fabian, Paul H. Denavit, William E. Hovan, III, Gregory A. Davidson
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Patent number: 9162419Abstract: A laminate design is provided and includes a substrate formed to define through-holes, an initially uncured pre-preg laminate disposed proximate to the substrate and an initially uncured pre-preg staple. The staple includes a main member and legs extending from the main member and being disposable with the legs extending through the through-holes to pierce the laminate. The staple is co-curable with the laminate.Type: GrantFiled: October 2, 2013Date of Patent: October 20, 2015Assignee: SIKORSKY AIRCRAFT CORPORATIONInventors: Jonathan Bremmer, Darryl Mark Toni, Jeffrey G. Sauer, William E. Hovan, Christian A. Rogg, Andrew Varga, David M. Lent, Robert A. Lacko, Allan R. Macallister
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Patent number: 9114586Abstract: A caul system for a composite structure having one or more core elements includes a lattice grid hard caul selectively locatable at a portion of the composite structure without core elements. The caul system further includes a soft caul selectively locatable at a portion of the composite structure having a core element. A method of forming a composite structure with one or more core elements includes locating a first laminate in a tool and locating one or more core elements over the first laminate. A second laminate is located over the one or more core elements. A lattice grid hard caul is placed over the second laminate, avoiding locations having core elements of the one or more core elements disposed thereat. A soft caul is located over the one or more core elements, thereby preventing deformation of the one or more core elements.Type: GrantFiled: February 9, 2012Date of Patent: August 25, 2015Assignee: SIKORSKY AIRCRAFT CORPORATIONInventors: Jonathan Bremmer, Paul H. Denavit, Edward Joseph Fabian, Jeffrey G. Sauer, William E. Hovan, III, Darryl Mark Toni
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Publication number: 20150136308Abstract: A kit for repairing an opening formed in a composite panel having a laminate skin arranged on opposing sides of a first core material is provided including a plug and a patch. The plug is formed from a second core material and has a cured filler material arranged within at least a portion of the second core material. The patch is formed from a plurality of cured first plies arranged in a stacked orientation. The plug is configured to be received within the opening of the composite panel and the patch is configured to cover the opening of the composite panel.Type: ApplicationFiled: November 21, 2013Publication date: May 21, 2015Applicant: Sikorsky Aircraft CorporationInventors: Jonathan Bremmer, Christian A. Rogg, Jeffrey G. Sauer, Darryl Mark Toni, Allan R. Macallister, Jr., William E. Hovan, III, Paul H. Denavit, Mihail Sirbu
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Publication number: 20150133016Abstract: A composite panel includes a support layer including a first plurality of prepreg plies wrapped around at least one mandrel; a mid-plane impact layer including a second plurality of prepreg plies, the mid-plane impact layer adjacent to the support layer; a upper skin layer including a third plurality of prepreg plies, the upper skin layer adjacent to the mid-place impact layer; and a lower skin layer including a fourth plurality of prepreg plies, the lower skin layer adjacent to the support layer; whereby each of the first, second, third, and fourth plurality of prepreg plies are co-cured to form the composite panel.Type: ApplicationFiled: November 12, 2013Publication date: May 14, 2015Applicant: Sikorsky Aircraft CorporationInventors: Jonathan Bremmer, Darryl Mark Toni, William E. Hovan, III, Allan R. Macallister, JR., Jeffrey G. Sauer, Christian A. Rogg, Robert A. Lacko, David M. Lent, Andrew Varga
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Publication number: 20150093541Abstract: A laminate design is provided and includes a substrate formed to define through-holes, an initially uncured pre-preg laminate disposed proximate to the substrate and an initially uncured pre-preg staple. The staple includes a main member and legs extending from the main member and being disposable with the legs extending through the through-holes to pierce the laminate. The staple is co-curable with the laminate.Type: ApplicationFiled: October 2, 2013Publication date: April 2, 2015Applicant: Sikorsky Aircraft CorporationInventors: Jonathan Bremmer, Darryl Mark Toni, Jeffrey G. Sauer, William E. Hovan, Christian A. Rogg, Andrew Varga, David M. Lent, Robert A. Lacko, Allan R. Macallister
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Publication number: 20140106116Abstract: A composite structure includes a first laminate and a second laminate. At least one core assembly is located between the first laminate and the second laminate. The at least one core assembly includes a core component and a layer of filler material disposed at a first face of the core component. The layer of filler material at least partially fills selected cells of the core component to a fill depth such that the filler material rigidizes when cured to prevent movement and/or crushing of core component under a pressure applied during a cure cycle of the composite structure.Type: ApplicationFiled: October 15, 2012Publication date: April 17, 2014Inventors: Jonathan Bremmer, Darryl Mark Toni, Jeffrey G. Sauer, Edward Joseph Fabian, Paul H. Denavit, William E. Hovan, III, Gergory A. Davidson
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Publication number: 20130344295Abstract: A caul system for a composite structure having one or more core elements includes a lattice grid hard caul selectively locatable at a portion of the composite structure without core elements. The caul system further includes a soft caul selectively locatable at a portion of the composite structure having a core element. A method of forming a composite structure with one or more core elements includes locating a first laminate in a tool and locating one or more core elements over the first laminate. A second laminate is located over the one or more core elements. A lattice grid hard caul is placed over the second laminate, avoiding locations having core elements of the one or more core elements disposed thereat. A soft caul is located over the one or more core elements, thereby preventing deformation of the one or more core elements.Type: ApplicationFiled: February 9, 2012Publication date: December 26, 2013Applicant: SIKORSKY AIRCRAFT CORPORATIONInventors: Jonathan Bremmer, Paul H. Denavit, Edward Joseph Fabian, Jeffrey G. Sauer, William E. Hovan, III, Darryl Mark Toni
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Publication number: 20130095284Abstract: A composite structure includes a first laminate, a second laminate, and at least one core component located between the first laminate and the second laminate. The at least one core component includes a honeycomb core and at least one locking ply extending from the honeycomb core between the first laminate and the second laminate. The at least one locking ply is configured such that a pressure applied during a cure cycle of the composite structure retains the at least one locking ply between the first laminate and the second laminate thereby preventing movement of core component.Type: ApplicationFiled: October 17, 2011Publication date: April 18, 2013Applicant: SIKORSKY AIRCRAFT CORPORATIONInventors: Jonathan Bremmer, Jeffrey G. Sauer, Edward Joseph Fabian, Paul H. Denavit, Darryl Mark Toni, William E. Hovan, III
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Patent number: 6513753Abstract: A main rotor support structure assembly includes a support housing which transmits loads developed by the main rotor assembly into the airframe. Integral main rotor servo attachment lugs extend from the cylindrical body member to provide lower attachment points for the rotor servo actuators which are operable to articulate a rotor swash plate or the like. The servo attachment lugs are integrally formed as part of the cylindrical body member and spaced thereabout. A substantially L-shaped metallic insert is sandwiched and bonded within each servo attachment lug to resist axial and transverse tension of the rather high forces exerted by the rotor servo actuators.Type: GrantFiled: August 14, 2001Date of Patent: February 4, 2003Assignee: Sikorsky Aircraft CorporationInventors: Darryl Mark Toni, Christos Kassapoglou, Jeffrey George Sauer, Darrel Duane Hornbaker
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Patent number: 5674586Abstract: A pressure tolerant composite panel has an inner fiber reinforced layer, an outer fiber reinforced layer and an core disposed therebetween. In one embodiment of the invention, the inner layer has weakening structures incorporated at the peripheral edges thereof, and has an outer layer of a different and lower modulus of elasticity than the inner layer to provide some degree of elongation. When high internal forces are encountered, the weakening structures allow the inner layer to separate, with the outer layers stretching to absorb the forces without failure. Optionally, strengthening straps are position about the panel such that it is compartmentalized into discrete sections to contain damage in localized areas. In an alternative embodiment of the invention, the inner core is produced of a crushable material which has a yield strength sufficient to provide structural support under normal operating conditions.Type: GrantFiled: June 7, 1995Date of Patent: October 7, 1997Assignee: United Technologies CorporationInventors: Darryl Mark Toni, Bruce Henry Barr, Edward Joseph Fabian, Bruce Fredric Kay, Joaquin Terceno, Kenneth Morgan Furnes, Alan Lee Dobyns