Patents by Inventor David G. Carlson

David G. Carlson 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).

  • Publication number: 20240317382
    Abstract: An aircraft is described and includes a fuselage; wings attached to the fuselage; and a torque box within the fuselage, the torque box including a side panel, the side panel comprising a composite laminate material including a plurality of stiffening beads integrated therewith.
    Type: Application
    Filed: March 22, 2023
    Publication date: September 26, 2024
    Applicant: Textron Innovations Inc.
    Inventors: Charles David Hogue, James Everett Kooiman, Joseph Richard Carpenter, JR., David G. Carlson, Jonathan Alexander Freeman
  • Patent number: 11820087
    Abstract: A method of preparing a composite article including providing a first bias assembly with a first bias roll; providing a first non-bias assembly with a first non-bias roll; positioning the first bias assembly to a dispensing position; dispensing a bias ply from the first bias roll along a bias path on a mold; cutting the bias ply; positioning the first non-bias assembly to a dispensing position; dispensing a non-bias ply from the first non-bias roll; and cutting the non-bias ply; wherein the bias path and the non-bias path are substantially parallel.
    Type: Grant
    Filed: October 22, 2021
    Date of Patent: November 21, 2023
    Assignee: Textron Innovations Inc.
    Inventors: David G. Carlson, Paul K. Oldroyd, George R. Decker, Doug K. Wolfe
  • Patent number: 11738493
    Abstract: In one embodiment, a method includes fastening a plurality of components of a composite structure in an assembly fixture, wherein the assembly fixture comprises a plurality of strands of a fiber-reinforced thermoplastic material, wherein the fiber-reinforced thermoplastic material comprises a thermoplastic embedded with a plurality of reinforcement fibers, wherein the plurality of reinforcement fibers is aligned within each strand of the plurality of strands, and wherein the assembly fixture further comprises an anisotropic thermal expansion property based on an orientation of the plurality of reinforcement fibers within the assembly fixture; and heating the assembly fixture in an autoclave to bond the plurality of components of the composite structure.
    Type: Grant
    Filed: April 27, 2021
    Date of Patent: August 29, 2023
    Assignee: TEXTRON INNOVATIONS INC.
    Inventors: David G. Carlson, Douglas K. Wolfe, James A. Cordell
  • Publication number: 20230211868
    Abstract: A folding step system includes a housing forming an interior space and a step comprising a step surface. The step is movable between a stowed configuration in which substantially all of the step surface is disposed within the interior space and a deployed configuration in which at least a portion of the step surface is disposed outside of the interior space and at least a portion of the step surface is disposed within the interior space.
    Type: Application
    Filed: January 5, 2022
    Publication date: July 6, 2023
    Applicant: Bell Textron Inc.
    Inventors: Michael Ross Wilkinson, James Everett Kooiman, Clegg Benjamin Brian Smith, Jeffrey Matthew Williams, Tjepke Heeringa, David G. Carlson
  • Publication number: 20230210253
    Abstract: An aircraft includes a fuselage having a former therein and a work platform system. The work platform system includes a platform that is moveable between a stowed configuration and a deployed configuration. The work platform system also has a hinge pin received by the platform. A platform stop is carried by the former and configured to inhibit rotation of the platform about the hinge pin when the platform is in the deployed configuration. The hinge pin is carried by the former.
    Type: Application
    Filed: January 5, 2022
    Publication date: July 6, 2023
    Applicant: Bell Textron Inc.
    Inventors: Michael Ross Wilkinson, James Everett Kooiman, Clegg Benjamin Brian Smith, Jeffrey Matthew Williams, Tjepke Heeringa, David G. Carlson
  • Patent number: 11628633
    Abstract: In one aspect, there is a composite skin for a tiltrotor aircraft including a first skin having a periphery defined by a forward edge, an aft edge, and outboard ends; a second skin; and a honeycomb core disposed between the first skin and the second skin, the honeycomb core comprised of a plurality of honeycomb panels positioned along the longitudinal axis of the first skin, the plurality of honeycomb panels having an array of large cells, each cell having a width of at least 1 cm; wherein the second skin and the honeycomb core have an outer perimeter within the periphery of the first skin.
    Type: Grant
    Filed: September 21, 2020
    Date of Patent: April 18, 2023
    Assignee: Textron Innovations Inc.
    Inventors: David G. Carlson, John R. McCullough, Douglas K. Wolfe, Andrew G. Baines, George R. Decker
  • Patent number: 11628601
    Abstract: One embodiment is an apparatus including a mold configured to manufacture a composite structure at a heated temperature. The mold includes a first mold tool configured to mold a first portion of the composite structure, wherein the first mold tool comprises a plurality of strands of a fiber-reinforced thermoplastic material, wherein the fiber-reinforced thermoplastic material comprises a thermoplastic embedded with a plurality of reinforcement fibers, wherein the plurality of reinforcement fibers is aligned within each strand of the plurality of strands; and an anisotropic thermal expansion property, wherein the anisotropic thermal expansion property is based on an orientation of the plurality of reinforcement fibers within the first mold tool; and a second mold tool configured to mold a second portion of the composite structure.
    Type: Grant
    Filed: July 16, 2021
    Date of Patent: April 18, 2023
    Assignee: TEXTRON INNOVATIONS LLC
    Inventor: David G. Carlson
  • Patent number: 11560222
    Abstract: A duct for a ducted-rotor aircraft may include an internal structure and an aerodynamic exterior skin that is adhesively bonded to the internal structure. The skin may include a leading-edge portion disposed at an inlet of the duct and an inner portion disposed along an interior of the duct. The inner portion of the skin may be bonded to the internal structure with a first bondline of adhesive and the leading-edge portion of the skin may be bonded to the inner portion of the skin with a second bondline of adhesive. One or both of the first and second bondlines of adhesive may be of non-uniform thickness to take up tolerance stackups between the inner portion of the skin, the leading-edge portion of the skin, and the internal structure.
    Type: Grant
    Filed: November 8, 2019
    Date of Patent: January 24, 2023
    Assignee: Textron Innovations Inc.
    Inventors: Karl Schroeder, Timothy Brian Carr, David G. Carlson, Kevin Stump, William Anthony Amante, Joseph Richard Carpenter, Jr.
  • Publication number: 20220234310
    Abstract: A method of preparing a composite article including providing a first bias assembly with a first bias roll; providing a first non-bias assembly with a first non-bias roll; positioning the first bias assembly to a dispensing position; dispensing a bias ply from the first bias roll along a bias path on a mold; cutting the bias ply; positioning the first non-bias assembly to a dispensing position; dispensing a non-bias ply from the first non-bias roll; and cutting the non-bias ply; wherein the bias path and the non-bias path are substantially parallel.
    Type: Application
    Filed: October 22, 2021
    Publication date: July 28, 2022
    Applicant: Bell Textron Inc.
    Inventors: David G. Carlson, Paul K. Oldroyd, George R. Decker, Doug K. Wolfe
  • Patent number: 11305867
    Abstract: A hub assembly for a ducted-rotor aircraft includes a plurality of stator supports, a first integral fitting that attaches to first ends of the stator supports, and a second integral fitting that attaches to second ends of the stator supports. The first fitting includes a plurality of motor attachment portions configured to locate and support a motor of the ducted-rotor aircraft, a plurality of fairing mounts configured to support attachment of an aerodynamic fairing to the hub assembly, and a plurality of stator locators configured to locate respective ones of the plurality of stator supports for attachment to the hub assembly. The first fitting has a body portion with an annular wall that supports the motor attachment portions, the fairing mounts, and the stator locators. The first fitting may be fabricated as a monolith that includes the body portion, motor attachment portions, fairing mounts, and stator locators.
    Type: Grant
    Filed: November 8, 2019
    Date of Patent: April 19, 2022
    Assignee: Textron Innovations Inc.
    Inventors: Karl Schroeder, Christopher Marion Johnson, Joseph Richard Carpenter, Jr., David G. Carlson
  • Publication number: 20210339431
    Abstract: One embodiment is an apparatus including a mold configured to manufacture a composite structure at a heated temperature. The mold includes a first mold tool configured to mold a first portion of the composite structure, wherein the first mold tool comprises a plurality of strands of a fiber-reinforced thermoplastic material, wherein the fiber-reinforced thermoplastic material comprises a thermoplastic embedded with a plurality of reinforcement fibers, wherein the plurality of reinforcement fibers is aligned within each strand of the plurality of strands; and an anisotropic thermal expansion property, wherein the anisotropic thermal expansion property is based on an orientation of the plurality of reinforcement fibers within the first mold tool; and a second mold tool configured to mold a second portion of the composite structure.
    Type: Application
    Filed: July 16, 2021
    Publication date: November 4, 2021
    Applicant: Bell Helicopter Textron Inc.
    Inventor: David G. Carlson
  • Patent number: 11155048
    Abstract: A material dispensing system including a first frame and a first application head. The first application head supported by the first frame including a first bias ply assembly comprising a bias ply roll supported on a bias ply dispenser unit, the first bias ply assembly configured to pass bias ply material along a bias path; and a first non-bias ply assembly comprising a non-bias ply roll supported by a non-bias ply dispenser unit, the non-bias ply assembly configured to pass non-bias ply material along a non-bias path; wherein the bias path and the non-bias path are substantially parallel. Another aspect provides a material dispensing system including a first frame and a first application head supported thereby; and a second frame and a second application head supported thereby; wherein the first frame and the second frame move in an X direction during operation. Another aspect includes preparing a composite article.
    Type: Grant
    Filed: July 10, 2018
    Date of Patent: October 26, 2021
    Assignee: Bell Helicopter Textron Inc.
    Inventors: David G. Carlson, Paul K. Oldroyd, George R. Decker, Doug K. Wolfe
  • Publication number: 20210308926
    Abstract: In one embodiment, a method includes fastening a plurality of components of a composite structure in an assembly fixture, wherein the assembly fixture comprises a plurality of strands of a fiber-reinforced thermoplastic material, wherein the fiber-reinforced thermoplastic material comprises a thermoplastic embedded with a plurality of reinforcement fibers, wherein the plurality of reinforcement fibers is aligned within each strand of the plurality of strands, and wherein the assembly fixture further comprises an anisotropic thermal expansion property based on an orientation of the plurality of reinforcement fibers within the assembly fixture; and heating the assembly fixture in an autoclave to bond the plurality of components of the composite structure.
    Type: Application
    Filed: April 27, 2021
    Publication date: October 7, 2021
    Applicant: Bell Helicopter Textron Inc.
    Inventors: David G. Carlson, Douglas K. Wolfe, James A. Cordell
  • Patent number: 11123900
    Abstract: In one embodiment, a method may comprise heating a composite material into a viscous form, wherein the composite material comprises a thermoplastic and a plurality of reinforcement fibers, wherein the plurality of reinforcement fibers is randomly arranged within the thermoplastic. The method may further comprise extruding a plurality of strands of the composite material, wherein extruding the plurality of strands causes the plurality of reinforcement fibers within each strand to align. The method may further comprise arranging the plurality of strands of the composite material to form a mold tool, wherein the mold tool is configured to mold a composite structure at a heated temperature, and wherein the mold tool comprises an anisotropic thermal expansion property, wherein the anisotropic thermal expansion property is based on an orientation of the plurality of reinforcement fibers within the mold tool.
    Type: Grant
    Filed: September 20, 2017
    Date of Patent: September 21, 2021
    Assignee: Bell Helicopter Textron Inc.
    Inventor: David G. Carlson
  • Patent number: 11106588
    Abstract: Embodiments are provided for deferring allocation of storage for segments. The method includes receiving, at a first moment in time, a request to allocate a first segment within a memory. Information corresponding to the first segment is stored in a first entry in a hash table, and memory is allocated for the first segment. Information about the first segment is returned to an entity that requested the allocation of the first segment, where the first segment is not allocated auxiliary storage until predefined criteria are satisfied. At a second moment in time, upon receiving an indication to deallocate the first segment, memory corresponding to the first segment is deallocated, where the first segment is never allocated auxiliary storage and the first entry in the hash table is deleted.
    Type: Grant
    Filed: November 28, 2017
    Date of Patent: August 31, 2021
    Assignee: International Business Machines Corporation
    Inventors: William A. Brown, Michael Corrigan, Kevin C. Griffin, Glen W. Nelson, David G. Carlson
  • Patent number: 11077596
    Abstract: In one embodiment, an assembly fixture may include a base structure including a plurality of strands of a fiber-reinforced thermoplastic material comprising a thermoplastic embedded with a plurality of reinforcement fibers, wherein the plurality of reinforcement fibers is aligned within each strand of the plurality of strands, and wherein the base structure further comprises an anisotropic thermal expansion property based on an orientation of the plurality of reinforcement fibers within the base structure, The assembly fixture may further include a plurality of fastening structures coupled to the base structure, wherein the plurality of fastening structures is configured to fasten a plurality of components of a composite structure for assembly using a heated bonding process.
    Type: Grant
    Filed: March 10, 2020
    Date of Patent: August 3, 2021
    Assignee: Bell Helicopter Textron Inc.
    Inventors: David G. Carlson, Douglas K. Wolfe, James A. Cordell
  • Patent number: 11059561
    Abstract: A torque box rib includes an upper rib cap configured to be coupled to an upper skin of a wing, a lower rib cap configured to be coupled to a lower skin of the wing, a forward post configured to be coupled to a forward spar of the wing, an aft post configured to be coupled to an aft spar of the wing, and a rib web configured to be coupled to the upper rib cap, the lower rib cap, the forward post, and the aft post.
    Type: Grant
    Filed: January 14, 2018
    Date of Patent: July 13, 2021
    Assignee: Textron Innovations Inc.
    Inventors: James Everett Kooiman, David G. Carlson, George Ryan Decker, Jeffrey Matthew Williams, Douglas K. Wolfe
  • Publication number: 20210139139
    Abstract: A duct for a ducted-rotor aircraft may include an internal structure and an aerodynamic exterior skin that is adhesively bonded to the internal structure. The skin may include a leading-edge portion disposed at an inlet of the duct and an inner portion disposed along an interior of the duct. The inner portion of the skin may be bonded to the internal structure with a first bondline of adhesive and the leading-edge portion of the skin may be bonded to the inner portion of the skin with a second bondline of adhesive. One or both of the first and second bondlines of adhesive may be of non-uniform thickness to take up tolerance stackups between the inner portion of the skin, the leading-edge portion of the skin, and the internal structure.
    Type: Application
    Filed: November 8, 2019
    Publication date: May 13, 2021
    Applicant: Bell Textron Inc.
    Inventors: Karl Schroeder, Timothy Brian Carr, David G. Carlson, Kevin Stump, William Anthony Amante, Joseph Richard Carpenter, JR.
  • Publication number: 20210139131
    Abstract: A hub assembly for a ducted-rotor aircraft includes a plurality of stator supports, a first integral fitting that attaches to first ends of the stator supports, and a second integral fitting that attaches to second ends of the stator supports. The first fitting includes a plurality of motor attachment portions configured to locate and support a motor of the ducted-rotor aircraft, a plurality of fairing mounts configured to support attachment of an aerodynamic fairing to the hub assembly, and a plurality of stator locators configured to locate respective ones of the plurality of stator supports for attachment to the hub assembly. The first fitting has a body portion with an annular wall that supports the motor attachment portions, the fairing mounts, and the stator locators. The first fitting may be fabricated as a monolith that includes the body portion, motor attachment portions, fairing mounts, and stator locators.
    Type: Application
    Filed: November 8, 2019
    Publication date: May 13, 2021
    Applicant: Bell Textron Inc.
    Inventors: Karl Schroeder, Christopher Marion Johnson, Joseph Richard Carpenter, JR., David G. Carlson
  • Publication number: 20210101676
    Abstract: An annular spar for a ducted-rotor of an aircraft may be fabricated from composite material, such as carbon-fiber-reinforced plastic (CFRP). The spar may include an annular plate, a first circumferential flange that extends from an outer edge of the plate, and a second circumferential flange that extends from an inner edge of the plate. The first and second circumferential flanges may taper inwardly toward a center axis of the spar. The spar may be constructed of a plurality of layers of CFRP. One or more of the layers may be fabricated from a single ply of CFRP, and one or more other layers may be fabricated from a plurality of plies of CFRP. The spar may exhibit a coefficient of thermal expansion (CTE) that allows an associated tip gap to remain essentially constant throughout a range of operating temperatures.
    Type: Application
    Filed: October 5, 2019
    Publication date: April 8, 2021
    Applicant: Bell Textron Inc.
    Inventors: Karl Schroeder, William Anthony Amante, Joseph Richard Carpenter, JR., David G. Carlson