Patents by Inventor Dennis R. Malone

Dennis R. Malone 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).

  • Invar tooling
    Patent number: 6672125
    Abstract: A method for fabricating an Invar tool includes the step of superplastically forming an Invar facesheet for the tool. A tool header is provided, and the Invar facesheet is then formed with an SPF diaphragm driver to match the predetermined contour of the tool header. The Invar facesheet is then welded to the tool header. Forming the Invar facesheet is achieved by positioning the Invar facesheet between a superplastically formable diaphragm and a die having the predetermined contour. The diaphragm is heated to a predetermined superplastic temperature, and a predetermined pressure is applied to the diaphragm. Application of the predetermined pressure allows the diaphragm to cause the Invar facesheet to form against the predetermined contour of the die. Superplastically forming the Invar facesheet results in a negligible amount of excess scrap, reduces material costs, and reduces labor costs.
    Type: Grant
    Filed: January 21, 2003
    Date of Patent: January 6, 2004
    Assignee: The Boeing Company
    Inventors: Phillip E. Kenney, Jeffrey D. Fletcher, Dennis R. Malone, Lawrence B. Wilson
  • Invar forming method for making tooling
    Publication number: 20030132269
    Abstract: A method for fabricating an Invar tool includes the step of superplastically forming an Invar facesheet for the tool. A tool header is provided, and the Invar facesheet is then formed with an SPF diaphragm driver to match the predetermined contour of the tool header. The Invar facesheet is then welded to the tool header. Forming the Invar facesheet is achieved by positioning the Invar facesheet between a superplastically formable diaphragm and a die having the predetermined contour. The diaphragm is heated to a predetermined superplastic temperature, and a predetermined pressure is applied to the diaphragm. Application of the predetermined pressure allows the diaphragm to cause the Invar facesheet to form against the predetermined contour of the die. Superplastically forming the Invar facesheet results in a negligible amount of excess scrap, reduces material costs, and reduces labor costs.
    Type: Application
    Filed: January 21, 2003
    Publication date: July 17, 2003
    Inventors: Phillip E. Kenney, Jeffrey D. Fletcher, Dennis R. Malone, Lawrence B. Wilson
  • Invar forming method for making tooling
    Publication number: 20030132363
    Abstract: A method for fabricating an Invar tool includes the step of superplastically forming an Invar facesheet for the tool. A tool header is provided, and the Invar facesheet is then formed with an SPF diaphragm driver to match the predetermined contour of the tool header. The Invar facesheet is then welded to the tool header. Forming the Invar facesheet is achieved by positioning the Invar facesheet between a superplastically formable diaphragm and a die having the predetermined contour. The diaphragm is heated to a predetermined superplastic temperature, and a predetermined pressure is applied to the diaphragm. Application of the predetermined pressure allows the diaphragm to cause the Invar facesheet to form against the predetermined contour of the die. Superplastically forming the Invar facesheet results in a negligible amount of excess scrap, reduces material costs, and reduces labor costs.
    Type: Application
    Filed: January 21, 2003
    Publication date: July 17, 2003
    Inventors: Phillip E. Kenney, Jeffrey D. Fletcher, Dennis R. Malone, Lawrence B. Wilson
  • Invar forming method for making tooling
    Patent number: 6510601
    Abstract: A method for fabricating an Invar tool includes the step of superplastically forming an Invar facesheet for the tool. A tool header is provided, and the Invar facesheet is then formed with an SPF diaphragm driver to match the predetermined contour of the tool header. The Invar facesheet is then welded to the tool header. Forming the Invar facesheet is achieved by positioning the Invar facesheet between a superplastically formable diaphragm and a die having the predetermined contour. The diaphragm is heated to a predetermined superplastic temperature, and a predetermined pressure is applied to the diaphragm. Application of the predetermined pressure allows the diaphragm to cause the Invar facesheet to form against the predetermined contour of the die. Superplastically forming the Invar facesheet results in a negligible amount of excess scrap, reduces material costs, and reduces labor costs.
    Type: Grant
    Filed: March 20, 2000
    Date of Patent: January 28, 2003
    Assignee: The Boeing Company
    Inventors: Phillip E. Kenney, Jeffrey D. Fletcher, Dennis R. Malone, Lawrence B. Wilson