Patents by Inventor Dennis J. Hanks
Dennis J. Hanks 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: 11548242Abstract: A system and method for manufacturing composite parts has been developed which offers the ability to produce composite parts in an infusion resin process without the use of expensive preforms or tools. In addition, the methods of manufacturing composite parts described herein offer the ability to produce composite parts having complex structures without the need for complex tooling. The method of manufacturing and systems described herein typically include printing a part skeleton using an additive manufacturing process followed by infusing the part skeleton with resin and curing the resin infused part skeleton to form the composite part.Type: GrantFiled: April 3, 2020Date of Patent: January 10, 2023Assignee: The Boeing CompanyInventors: Benjamin J. Stephenson, Hugh A. Yap, Gwen Marie Lanphere Gross, William S. Hollensteiner, Scott K. Frankenbery, Dennis J. Hanks
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Publication number: 20200238636Abstract: A system and method for manufacturing composite parts has been developed which offers the ability to produce composite parts in an infusion resin process without the use of expensive preforms or tools. In addition, the methods of manufacturing composite parts described herein offer the ability to produce composite parts having complex structures without the need for complex tooling. The method of manufacturing and systems described herein typically include printing a part skeleton using an additive manufacturing process followed by infusing the part skeleton with resin and curing the resin infused part skeleton to form the composite part.Type: ApplicationFiled: April 3, 2020Publication date: July 30, 2020Inventors: Benjamin J. STEPHENSON, Hugh A. Yap, Gwen Marie Lanphere Gross, William S. Hollensteiner, Scott K. Frankenbery, Dennis J. Hanks
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Patent number: 10661513Abstract: A system and method for manufacturing composite parts has been developed which offers the ability to produce composite parts in an infusion resin process without the use of expensive preforms or tools. In addition, the methods of manufacturing composite parts described herein offer the ability to produce composite parts having complex structures without the need for complex tooling. The method of manufacturing and systems described herein typically include printing a part skeleton using an additive manufacturing process followed by infusing the part skeleton with resin and curing the resin infused part skeleton to form the composite part.Type: GrantFiled: December 1, 2015Date of Patent: May 26, 2020Assignee: THE BOEING COMPANYInventors: Benjamin J. Stephenson, Hugh A. Yap, Gwen Marie Lanphere Gross, William S. Hollensteiner, Scott K. Frankenbery, Dennis J. Hanks
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Publication number: 20170151721Abstract: A system and method for manufacturing composite parts has been developed which offers the ability to produce composite parts in an infusion resin process without the use of expensive preforms or tools. In addition, the methods of manufacturing composite parts described herein offer the ability to produce composite parts having complex structures without the need for complex tooling. The method of manufacturing and systems described herein typically include printing a part skeleton using an additive manufacturing process followed by infusing the part skeleton with resin and curing the resin infused part skeleton to form the composite part.Type: ApplicationFiled: December 1, 2015Publication date: June 1, 2017Inventors: Benjamin J. STEPHENSON, Hugh A. YAP, Gwen Marie LANPHERE GROSS, William S. HOLLENSTEINER, Scott K. FRANKENBERY, Dennis J. HANKS
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Patent number: 8974212Abstract: Methods and systems for manufacturing fiber-reinforced resin parts are disclosed herein. In one embodiment, a method for manufacturing a fiber-reinforced resin part includes positioning a plurality of fibers on a mold surface of a female tool, and covering the fibers with a sealing layer. The method further includes pressing a portion of the covered fibers against an interior transition region (e.g., an internal radius) of the mold surface. While the portion of covered fibers is pressed against the interior transition region, air is removed from between the sealing layer and the mold surface to draw at least a partial vacuum between the sealing layer and the mold surface.Type: GrantFiled: October 9, 2009Date of Patent: March 10, 2015Assignee: The Boeing CompanyInventors: Thomas R. Cundiff, Dennis J. Hanks, Jack A. Woods, Val G. Brustad, Andrew E. Modin
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Publication number: 20100074979Abstract: Methods and systems for manufacturing fiber-reinforced resin parts are disclosed herein. In one embodiment, a method for manufacturing a fiber-reinforced resin part includes positioning a plurality of fibers on a mold surface of a female tool, and covering the fibers with a sealing layer. The method further includes pressing a portion of the covered fibers against an interior transition region (e.g., an internal radius) of the mold surface. While the portion of covered fibers is pressed against the interior transition region, air is removed from between the sealing layer and the mold surface to draw at least a partial vacuum between the sealing layer and the mold surface.Type: ApplicationFiled: October 9, 2009Publication date: March 25, 2010Applicant: The Boeing CompanyInventors: Thomas R. Cundiff, Dennis J. Hanks, Jack A. Woods, Val G. Brustad, Andrew E. Modin
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Publication number: 20100040722Abstract: A composite item is fabricated in system that includes a layer of preform, supply of resin, mandrel, and bagging film. The layer of preform corresponds to the composite item. The supply of resin is sufficient to infuse the preform. The mandrel includes a preform receiving zone to receive the layer of preform and a resin receiving zone to receive the supply of resin. The resin receiving zone is adjacent to the preform receiving zone. The bagging film is operable to generate an envelope surrounding the preform receiving zone and the resin receiving zone.Type: ApplicationFiled: November 3, 2009Publication date: February 18, 2010Applicant: The Boeing CompanyInventors: Michael L. Glain, Dennis J. Hanks, Andrew E. Modin, Jack A. Woods, Timothy D. Aquino
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Patent number: 7633040Abstract: A composite item is fabricated in system that includes a layer of preform, supply of resin, mandrel, and bagging film. The layer of preform corresponds to the composite item. The supply of resin is sufficient to infuse the preform. The mandrel includes a preform receiving zone to receive the layer of preform and a resin receiving zone to receive the supply of resin. The resin receiving zone is adjacent to the preform receiving zone. The bagging film is operable to generate an envelope surrounding the preform receiving zone and the resin receiving zone.Type: GrantFiled: November 14, 2005Date of Patent: December 15, 2009Assignee: The Boeing CompanyInventors: Michael L. Glain, Dennis J. Hanks, Andrew E. Modin, Jack A. Woods, Timothy D. Aquino
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Patent number: 7622066Abstract: Methods and systems for manufacturing fiber-reinforced resin parts are disclosed herein. In one embodiment, a method for manufacturing a fiber-reinforced resin part includes positioning a plurality of fibers on a mold surface of a female tool, and covering the fibers with a sealing layer. The method further includes pressing a portion of the covered fibers against an interior transition region (e.g., an internal radius) of the mold surface. While the portion of covered fibers is pressed against the interior transition region, air is removed from between the sealing layer and the mold surface to draw at least a partial vacuum between the sealing layer and the mold surface.Type: GrantFiled: July 26, 2004Date of Patent: November 24, 2009Assignee: The Boeing CompanyInventors: Val G. Brustad, Thomas R. Cundiff, Dennis J. Hanks, Jack A. Woods, Andrew E. Modin
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Patent number: 7585448Abstract: The disclosure is directed to a process for producing resin infused composite parts having improved structural performance and improved surface appearance. The process comprises the steps of positioning a dry composite preform on a forming tool component, arranging resin exit lines in close proximity to the perform, placing a permeable release material on the perform, and placing a first piece of flow media over the release material. The process further comprises the steps of wrapping a resin distribution tube with a second piece of flow media, placing a vacuum bag layer over the forming tool component, preform, release material, first and second pieces of flow media and resin distribution tube, such that the resin distribution tube is retained in a pleat formed in the vacuum bag layer and such that a bagged preform is formed, and positioning the resin distribution tube above the bagged preform.Type: GrantFiled: September 28, 2006Date of Patent: September 8, 2009Assignee: The Boeing CompanyInventors: Dennis J. Hanks, Jack A. Woods, Kate J. Felde
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Publication number: 20080079193Abstract: The invention is directed to a process for elimination of deformations on resin infused composite parts in which the resin distribution tube used in a resin vacuum infusion process is positioned above the surface of a preform and is not in contact with the preform. Flow media indirectly connects the resin distribution tube to the preform which allows for free movement of resin without direct contact of the resin distribution tube to the perform, and thus, this eliminates deformations that are caused by direct contact of the resin distribution tube to the preform.Type: ApplicationFiled: September 28, 2006Publication date: April 3, 2008Inventors: Dennis J. Hanks, Jack A. Woods, Kate J. Felde
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Patent number: 7334782Abstract: By evacuating the resin feed tank to a pressure below atmospheric pressure, employing cyclic compaction, and controlling the net compaction pressure, we are better able to control a resin infusion process, particularly a vacuum assisted resin transfer molding process, and produce aerospace-grade fiber-reinforced resin composite having fiber volume fractions and tool-side surface finishes comparable to or exceeding those made using an autoclave.Type: GrantFiled: May 28, 2003Date of Patent: February 26, 2008Assignee: The Boeing CompanyInventors: Jack A Woods, Andrew E. Modin, Robert D. Hawkins, Dennis J. Hanks