Patents by Inventor Dennis Lynn Coad
Dennis Lynn Coad 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: 20230383412Abstract: Implementations are provided for fabricating a finished workpiece having a shaped portion. One implementation includes: a superplastic formation diffusion bonding (SPFDB) component; a cold spray additive manufacturing (CSAM) component; and a mold having a concavity. Various configurations can operate on a workpiece with the SPFDB and CSAM components in different orders. An implementation is configured to cold spray (with the CSAM component) an additive material onto the workpiece; and perform superplastic forming (with the SPFDB component) on the workpiece with the mold, thereby rendering the workpiece into the finished workpiece having the shaped portion. The shaped portion conforms to a shape defined by the concavity. Cold spraying results in an increased thickness of the finished workpiece in a target region, which can provide structural reinforcement, and which can have a tapered edge. The workpiece can be a metal substrate made of titanium, aluminum, stainless steel, or another material.Type: ApplicationFiled: August 2, 2023Publication date: November 30, 2023Applicant: The Boeing CompanyInventors: Bruno Zamorano Senderos, Dennis Lynn Coad, Daniel G. Sanders
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Patent number: 11753723Abstract: Implementations are provided for fabricating a finished workpiece having a shaped portion. One implementation includes: a superplastic formation diffusion bonding (SPFDB) component; a cold spray additive manufacturing (CSAM) component; and a mold having a concavity. Various configurations can operate on a workpiece with the SPFDB and CSAM components in different orders. An implementation is configured to cold spray (with the CSAM component) an additive material onto the workpiece; and perform superplastic forming (with the SPFDB component) on the workpiece with the mold, thereby rendering the workpiece into the finished workpiece having the shaped portion. The shaped portion conforms to a shape defined by the concavity. Cold spraying results in an increased thickness of the finished workpiece in a target region, which can provide structural reinforcement, and which can have a tapered edge. The workpiece can be a metal substrate made of titanium, aluminum, stainless steel, or another material.Type: GrantFiled: June 2, 2020Date of Patent: September 12, 2023Assignee: THE BOEING COMPANYInventors: Bruno Zamorano Senderos, Dennis Lynn Coad, Daniel G. Sanders
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Patent number: 11624722Abstract: Described herein are dielectric fluid testers for determining dielectric breakdown of fluid samples, systems comprising such testers, and methods using thereof. A dielectric fluid tester comprises a container and two electrodes. The test heads of these electrodes protrude inside the container and face each other, forming a gap. In some examples, one or both electrodes are movable for adjusting the gap and/or the volume inside the container available for a fluid sample. For example, the container includes two internal seals, one of which has a fixed position and is slidably coupled to a respective electrode. The other seal is slidably coupled to the container and moves together with the corresponding electrode. The container comprises an access port, providing a fluid communication between the fluid sample and an external pressure-controlling source. In some examples, the access port is used to deliver and remove the fluid sample from the container.Type: GrantFiled: April 24, 2020Date of Patent: April 11, 2023Assignee: THE BOEING COMPANYInventors: Garnel King, Dennis Lynn Coad
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Patent number: 11255641Abstract: A compositionally-graded structure including a body having a first major surface and a second major surface opposed from the first major surface along a thickness axis, the body including a metallic component and a ceramic component, wherein a concentration of the ceramic component in the body is a function of location within the body along the thickness axis, wherein transitions of the concentration of the ceramic component in the body are continuous such that distinct interfaces are not macroscopically established within the body, and wherein the concentration of the ceramic component is at least 95 percent by volume at at least one location within the body along the thickness axis.Type: GrantFiled: June 4, 2020Date of Patent: February 22, 2022Assignee: The Boeing CompanyInventors: Bruno Zamorano Senderos, Dennis Lynn Coad, James Ross Dobbs, Ali Yousefiani
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Publication number: 20210371986Abstract: Implementations are provided for fabricating a finished workpiece having a shaped portion. One implementation includes: a superplastic formation diffusion bonding (SPFDB) component; a cold spray additive manufacturing (CSAM) component; and a mold having a concavity. Various configurations can operate on a workpiece with the SPFDB and CSAM components in different orders. An implementation is configured to cold spray (with the CSAM component) an additive material onto the workpiece; and perform superplastic forming (with the SPFDB component) on the workpiece with the mold, thereby rendering the workpiece into the finished workpiece having the shaped portion. The shaped portion conforms to a shape defined by the concavity. Cold spraying results in an increased thickness of the finished workpiece in a target region, which can provide structural reinforcement, and which can have a tapered edge. The workpiece can be a metal substrate made of titanium, aluminum, stainless steel, or another material.Type: ApplicationFiled: June 2, 2020Publication date: December 2, 2021Inventors: Bruno Zamorano Senderos, Dennis Lynn Coad, Daniel G. Sanders
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Publication number: 20210333229Abstract: Described herein are dielectric fluid testers for determining dielectric breakdown of fluid samples, systems comprising such testers, and methods using thereof. A dielectric fluid tester comprises a container and two electrodes. The test heads of these electrodes protrude inside the container and face each other, forming a gap. In some examples, one or both electrodes are movable for adjusting the gap and/or the volume inside the container available for a fluid sample. For example, the container includes two internal seals, one of which has a fixed position and is slidably coupled to a respective electrode. The other seal is slidably coupled to the container and moves together with the corresponding electrode. The container comprises an access port, providing a fluid communication between the fluid sample and an external pressure-controlling source. In some examples, the access port is used to deliver and remove the fluid sample from the container.Type: ApplicationFiled: April 24, 2020Publication date: October 28, 2021Applicant: The Boeing CompanyInventors: Garnel King, Dennis Lynn Coad
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Publication number: 20210291431Abstract: Implementations provide cold spray additive manufacturing (“CSAM”)-based fabrication of a complex multi curvature part (“CMCP”) by cold spraying onto a mold. Implementations achieve the desired shape and dimensions of a CMCP having variable surface thicknesses and utilize reinforcements integrated during CSAM. Reinforcements are integral to each CMCP as soon as fabrication is complete, and maintain stiffness, avoid fluttering, and provide other similar benefits. Implementations provide a stiff CMCP with multiple curvatures having fully controllable variable thicknesses. Integral reinforcements added during fabrication avoid tolerance issues by avoiding coupling non-reinforced CMCPs to reinforcements or other post-fabrication adjustments. CSAM-based CMCPs, having directly integrated reinforcements, exhibit superior tolerances that do not need to be re-worked or otherwise corrected after fabrication. Reinforcement attachment methods that have complex load transfer behavior are not necessary.Type: ApplicationFiled: March 23, 2020Publication date: September 23, 2021Inventors: Bruno Zamorano Senderos, Dennis Lynn COAD, Kenneth W. YOUNG
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Patent number: 11024435Abstract: Radiation-shielding composite materials and their methods of manufacture. Such methods may include adding a metal hydride to a hardenable matrix precursor, adding a reinforcing material to the hardenable matrix precursor, and hardening the matrix precursor to form a composite material that incorporates the reinforcing material and the metal hydride in a solid matrix. The resulting radiation-shielding composite materials are configured to attenuate incident radiation, and may be used in the construction of panels, laminate structures, buildings, and aerospace vehicles, among others.Type: GrantFiled: November 2, 2018Date of Patent: June 1, 2021Assignee: The Boeing CompanyInventors: Robert Jerrell Harris, Jr., Dennis Lynn Coad, James Ross Dobbs, William Atwell
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Patent number: 11009435Abstract: A test fixture configured to attach to and apply a tensile force to a test specimen. The test fixture may include a first clevis section and a second clevis section that are each configured to be attached to the test specimen. Each of the first and second clevis sections may include a fixed block and a movable block. Connectors connect the clevis sections together and hold the test specimen. The first and second clevis sections may be moved apart to apply a force to the attached test specimen to test one or more properties of the test specimen.Type: GrantFiled: May 16, 2019Date of Patent: May 18, 2021Assignee: THE BOEING COMPANYInventors: Dennis Lynn Coad, Bruno Zamorano Senderos, Garnel King, Stefanie Anita Meier, Rogie I. Rodriguez
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Patent number: 10919191Abstract: Methods provide for creating a three-dimensional random fiber orientation in a composite component. According to embodiments described herein, narrow flakes are created from a unidirectional composite fiber tape and poured into a reservoir of a mold, creating a three-dimensional random fiber orientation of the narrow flakes within the reservoir. At least a majority of the narrow flakes have an aspect ratio of length to width of at least 6:1. The narrow flakes are heated and compressed to fill the mold and create the composite component. The three-dimensional random fiber orientation of the narrow flakes within the reservoir is maintained as the narrow flakes are pushed through the mold, creating consistent, uniform strength characteristics throughout the resulting composite component.Type: GrantFiled: November 1, 2019Date of Patent: February 16, 2021Assignee: The Boeing CompanyInventors: Edward McMurray Fisher, Jr., Dennis Lynn Coad, Brian Allen Carter, Glenn David Hardin, Jon Paul Thurber, Douglas Eugene Bailey
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Patent number: 10919192Abstract: Methods provide for creating a three-dimensional random fiber orientation in a composite component. According to embodiments described herein, narrow flakes are created from a unidirectional composite fiber tape and poured into a reservoir of a mold, creating a three-dimensional random fiber orientation of the narrow flakes within the reservoir. At least a majority of the narrow flakes have an aspect ratio of length to width of at least 6:1. The narrow flakes are heated and compressed to fill the mold and create the composite component. The three-dimensional random fiber orientation of the narrow flakes within the reservoir is maintained as the narrow flakes are pushed through the mold, creating consistent, uniform strength characteristics throughout the resulting composite component.Type: GrantFiled: November 1, 2019Date of Patent: February 16, 2021Assignee: The Boeing CompanyInventors: Edward McMurray Fisher, Jr., Dennis Lynn Coad, Brian Allen Carter, Glenn David Hardin, Jon Paul Thurber, Douglas Eugene Bailey
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Publication number: 20200363302Abstract: A test fixture configured to attach to and apply a tensile force to a test specimen. The test fixture may include a first clevis section and a second clevis section that are each configured to be attached to the test specimen. Each of the first and second clevis sections may include a fixed block and a movable block. Connectors connect the clevis sections together and hold the test specimen. The first and second clevis sections may be moved apart to apply a force to the attached test specimen to test one or more properties of the test specimen.Type: ApplicationFiled: May 16, 2019Publication date: November 19, 2020Inventors: Dennis Lynn Coad, Bruno Zamorano Senderos, Garnel King, Stefanie Anita Meier, Rogie I. Rodriguez
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Publication number: 20200326160Abstract: A compositionally-graded structure including a body having a first major surface and a second major surface opposed from the first major surface along a thickness axis, the body including a metallic component and a ceramic component, wherein a concentration of the ceramic component in the body is a function of location within the body along the thickness axis, wherein transitions of the concentration of the ceramic component in the body are continuous such that distinct interfaces are not macroscopically established within the body, and wherein the concentration of the ceramic component is at least 95 percent by volume at at least one location within the body along the thickness axis.Type: ApplicationFiled: June 4, 2020Publication date: October 15, 2020Applicant: The Boeing CompanyInventors: Bruno Zamorano Senderos, Dennis Lynn Coad, James Ross Dobbs, Ali Yousefiani
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Publication number: 20200143951Abstract: Radiation-shielding composite materials and their methods of manufacture. Such methods may include adding a metal hydride to a hardenable matrix precursor, adding a reinforcing material to the hardenable matrix precursor, and hardening the matrix precursor to form a composite material that incorporates the reinforcing material and the metal hydride in a solid matrix. The resulting radiation-shielding composite materials are configured to attenuate incident radiation, and may be used in the construction of panels, laminate structures, buildings, and aerospace vehicles, among others.Type: ApplicationFiled: November 2, 2018Publication date: May 7, 2020Applicant: The Boeing CompanyInventors: Robert Jerrell Harris, JR., Dennis Lynn Coad, James Ross Dobbs, William Atwell
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Patent number: 10603821Abstract: Methods provide for creating a three-dimensional random fiber orientation in a composite component. According to embodiments described herein, narrow flakes are created from a unidirectional composite fiber tape and poured into a reservoir of a mold, creating a three-dimensional random fiber orientation of the narrow flakes within the reservoir. At least a majority of the narrow flakes have an aspect ratio of length to width of at least 6:1. The narrow flakes are heated and compressed to fill the mold and create the composite component. The three-dimensional random fiber orientation of the narrow flakes within the reservoir is maintained as the narrow flakes are pushed through the mold, creating consistent, uniform strength characteristics throughout the resulting composite component.Type: GrantFiled: January 23, 2012Date of Patent: March 31, 2020Assignee: The Boeing CompanyInventors: Edward McMurray Fisher, Jr., Dennis Lynn Coad, Brian Allen Carter, Glenn David Hardin, Jon Paul Thurber, Douglas Eugene Bailey
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Publication number: 20200061881Abstract: Methods provide for creating a three-dimensional random fiber orientation in a composite component. According to embodiments described herein, narrow flakes are created from a unidirectional composite fiber tape and poured into a reservoir of a mold, creating a three-dimensional random fiber orientation of the narrow flakes within the reservoir. At least a majority of the narrow flakes have an aspect ratio of length to width of at least 6:1. The narrow flakes are heated and compressed to fill the mold and create the composite component. The three-dimensional random fiber orientation of the narrow flakes within the reservoir is maintained as the narrow flakes are pushed through the mold, creating consistent, uniform strength characteristics throughout the resulting composite component.Type: ApplicationFiled: November 1, 2019Publication date: February 27, 2020Applicant: The Boeing CompanyInventors: Edward McMurray Fisher,, JR., Dennis Lynn Coad, Brian Allen Carter, Glenn David Hardin, Jon Paul Thurber, Douglas Eugene Bailey
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Publication number: 20200061880Abstract: Methods provide for creating a three-dimensional random fiber orientation in a composite component. According to embodiments described herein, narrow flakes are created from a unidirectional composite fiber tape and poured into a reservoir of a mold, creating a three-dimensional random fiber orientation of the narrow flakes within the reservoir. At least a majority of the narrow flakes have an aspect ratio of length to width of at least 6:1. The narrow flakes are heated and compressed to fill the mold and create the composite component. The three-dimensional random fiber orientation of the narrow flakes within the reservoir is maintained as the narrow flakes are pushed through the mold, creating consistent, uniform strength characteristics throughout the resulting composite component.Type: ApplicationFiled: November 1, 2019Publication date: February 27, 2020Applicant: The Boeing CompanyInventors: Edward McMurray Fisher, JR., Dennis Lynn Coad, Brian Allen Carter, Glenn David Hardin, Jon Paul Thurber, Douglas Eugene Bailey
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Publication number: 20190072365Abstract: A compositionally-graded structure including a body having a first major surface and a second major surface opposed from the first major surface along a thickness axis, the body including a metallic component and a ceramic component, wherein a concentration of the ceramic component in the body is a function of location within the body along the thickness axis, wherein transitions of the concentration of the ceramic component in the body are continuous such that distinct interfaces are not macroscopically established within the body, and wherein the concentration of the ceramic component is at least 95 percent by volume at at least one location within the body along the thickness axis.Type: ApplicationFiled: September 5, 2017Publication date: March 7, 2019Applicant: The Boeing CompanyInventors: Bruno Zamorano Senderos, Dennis Lynn Coad, James R. Dobbs, Ali Yousefiani
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Publication number: 20130189478Abstract: Methods provide for creating a three-dimensional random fiber orientation in a composite component. According to embodiments described herein, narrow flakes are created from a unidirectional composite fiber tape and poured into a reservoir of a mold, creating a three-dimensional random fiber orientation of the narrow flakes within the reservoir. At least a majority of the narrow flakes have an aspect ratio of length to width of at least 6:1. The narrow flakes are heated and compressed to fill the mold and create the composite component. The three-dimensional random fiber orientation of the narrow flakes within the reservoir is maintained as the narrow flakes are pushed through the mold, creating consistent, uniform strength characteristics throughout the resulting composite component.Type: ApplicationFiled: January 23, 2012Publication date: July 25, 2013Inventors: Edward McMurray Fisher, JR., Dennis Lynn Coad, Brian Allen Carter, Glenn David Hardin, Jon Paul Thurber, Douglas Eugene Bailey