Patents by Inventor Douglas A. McCarville

Douglas A. McCarville 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).

  • COMPOSITE SANDWICH SHELL EDGE JOINT
    Publication number: 20120128408
    Abstract: A composite sandwich shell edge joint includes an outboard buildup pad, an inboard buildup pad spaced-apart and adjacent to the outboard buildup pad, an outboard face sheet extending from the outboard buildup pad, an inboard face sheet extending from the inboard buildup pad, bridging plies connecting the outboard buildup pad and the inboard buildup pad and at least one barrel nut installed in the buildup pads.
    Type: Application
    Filed: November 19, 2010
    Publication date: May 24, 2012
    Inventors: MICHAEL LESLIE HAND, Douglas A. McCarville
  • METHOD FOR JOINING SANDWICH TRUSS CORE PANELS AND COMPOSITE STRUCTURES PRODUCED THEREFROM
    Publication number: 20120090265
    Abstract: Fluted core sandwich panels are joined together to form a composite structure. Variations in panel ends are accommodated by a core stiffener insert installed in a joint between ends of the panels.
    Type: Application
    Filed: October 19, 2010
    Publication date: April 19, 2012
    Inventors: DOUGLAS A. MCCARVILLE, Juan C. Guzman, Michael Leslie Hand
  • METHOD AND DEVICE FOR FORMING JOINTS IN COMPOSITE STRUCTURES
    Publication number: 20120084959
    Abstract: A tool is used to form a joint between a composite dome and a surrounding composite skirt. The tool includes a tool shell on which composite plies may be laid up to form the skirt and a spacer connected with the shell for filling a gap between the dome and the skirt.
    Type: Application
    Filed: October 6, 2010
    Publication date: April 12, 2012
    Inventors: MICHAEL LESLIE HAND, Douglas A. McCarville, Jennifer S. Noel
  • Composite Truss Panel Having Fluted Core
    Publication number: 20110300343
    Abstract: A composite truss structure employs a sandwich-in-sandwich construction in which a composite fluted core is sandwiched between two facesheets, and at least one structural foam stiffener is sandwiched within the core or between the facesheets and/or the core.
    Type: Application
    Filed: August 16, 2011
    Publication date: December 8, 2011
    Applicant: THE BOEING COMPANY
    Inventors: Douglas A. McCarville, Juan C. Guzman, Michael L. Hand, Michael J. Robinson
  • Method for making composite truss panel having a fluted core
    Patent number: 7998299
    Abstract: A composite truss structure employs a sandwich-in-sandwich construction in which a composite fluted core is sandwiched between two facesheets, and at least one structural foam stiffener is sandwiched within the core or between the facesheets and/or the core.
    Type: Grant
    Filed: October 1, 2008
    Date of Patent: August 16, 2011
    Assignee: The Boeing Company
    Inventors: Douglas A. McCarville, Juan C. Guzman, Michael L. Hand, Michael J. Robinson
  • Foam Stiffened Hollow Composite Stringer
    Publication number: 20110111183
    Abstract: A method and apparatus for a composite stringer. A method is used for manufacturing a hollow composite stringer. Foam is formed with a mandrel installed into the foam. A composite material and the foam is laid up onto a tool in a form of a stringer. The composite material and the foam in the form of the stringer is cured to form a cured stringer. The mandrel from the foam is removed to form the hollow composite stringer.
    Type: Application
    Filed: January 13, 2011
    Publication date: May 12, 2011
    Applicant: THE BOEING COMPANY
    Inventors: Juan C. Guzman, Douglas A. McCarville, Daniel M. Rotter, Barry P. VanWest
  • CURVED COMPOSITE FRAMES AND METHOD OF MAKING THE SAME
    Publication number: 20110097554
    Abstract: A curved composite aircraft frame comprises a multi-ply composite laminate having a generally Z-shaped cross section. At least certain of the laminate plies include unidirectional reinforcing fibers that are substantially tangent at substantially all points along the curvature of the frame.
    Type: Application
    Filed: May 10, 2010
    Publication date: April 28, 2011
    Inventors: David J. Kehrl, Kent E. Johnson, Douglas A. McCarville
  • SHAPED COMPOSITE STRINGERS AND METHODS OF MAKING
    Publication number: 20110088833
    Abstract: A stiffened skin panel of an aircraft that includes an aircraft skin panel of composite material and a composite stringer consolidated with the aircraft skin panel. The stringer has a pair of stringer sides, each extending from a stringer top to a stringer leg. The stringer sides may each extend through a wide radius, smooth continuous curve to a stringer leg. The wide radius, smooth continuous curve may be proximate the base of the stringer side in a region where the stringer side transitions to the stringer leg.
    Type: Application
    Filed: December 22, 2010
    Publication date: April 21, 2011
    Applicant: THE BOEING COMPANY
    Inventors: Juan C. Guzman, Douglas A. McCarville, Daniel M. Rotter, Brian G. Robins
  • Multi-Functional Aircraft Structures
    Publication number: 20110027526
    Abstract: A method and apparatus for manufacturing a composite structure. A filler material with a barrier material for a channel in the filler material is formed. A composite material and the filler material with the barrier material are laid up onto a tool in a shape of the composite structure. The composite material and the filler material in the shape of the composite structure are cured.
    Type: Application
    Filed: August 3, 2009
    Publication date: February 3, 2011
    Applicant: THE BOEING COMPANY
    Inventors: Douglas A. McCarville, Juan C. Guzman, Daniel M. Rotter
  • Foam stiffened hollow composite stringer
    Patent number: 7879276
    Abstract: A method and apparatus for a composite stringer. A method is used for manufacturing a hollow composite stringer. Foam is formed with a mandrel installed into the foam. A composite material and the foam is laid up onto a tool in a form of a stringer. The composite material and the foam in the form of the stringer is cured to form a cured stringer. The mandrel from the foam is removed to form the hollow composite stringer.
    Type: Grant
    Filed: November 8, 2007
    Date of Patent: February 1, 2011
    Assignee: The Boeing Company
    Inventors: Juan C. Guzman, Douglas A. McCarville, Daniel M. Rotter, Barry P. Van West
  • Shaped composite stringers and methods of making
    Patent number: 7861969
    Abstract: A stiffened skin panel of an aircraft that includes an aircraft skin panel of composite material and a composite stringer consolidated with the aircraft skin panel. The stringer has a pair of stringer sides, each extending from a stringer top to a stringer leg. The stringer sides may each extend through a wide radius, smooth continuous curve to a stringer leg. The wide radius, smooth continuous curve may be proximate the base of the stringer side in a region where the stringer side transitions to the stringer leg.
    Type: Grant
    Filed: May 24, 2007
    Date of Patent: January 4, 2011
    Assignee: The Boeing Company
    Inventors: Juan C. Guzman, Douglas A. McCarville, Daniel M. Rotter, Brian G. Robins
  • REINFORCED FOAM-FILLED COMPOSITE STRINGER
    Publication number: 20100129589
    Abstract: A method and apparatus for manufacturing a composite stringer. A composite material and foam are laid up onto a tool in the form of a stringer. The foam has a plurality of structural members within the foam. The plurality of structural members has a number of orientations to resist a number of loads. The composite material, the foam in the form of the stringer, and the plurality of structural members are cured to form the composite stringer.
    Type: Application
    Filed: November 25, 2008
    Publication date: May 27, 2010
    Inventors: Simon D. Senibi, Barry P. Van West, Juan Carlos Guzman, Douglas A. McCarville, Daniel M. Rotter
  • WRINKLE REDUCTION IN UNCURED COMPOSITE LAMINATES
    Publication number: 20100078845
    Abstract: Wrinkles are removed from fiber reinforced resin plies of an uncured composite layup by subjecting the wrinkles to vibration and pressure.
    Type: Application
    Filed: September 30, 2008
    Publication date: April 1, 2010
    Inventors: Juan C. Guzman, Douglas McCarville, Daniel M. Rotter, Todd J. Washburn, Kurtis S. Willden, Donald C. Darrow
  • COMPOSITE TRUSS PANEL HAVING FLUTED CORE AND METHOD FOR MAKING THE SAME
    Publication number: 20100080941
    Abstract: A composite truss structure employs a sandwich-in-sandwich construction in which a composite fluted core is sandwiched between two facesheets, and at least one structural foam stiffener is sandwiched within the core or between the facesheets and/or the core.
    Type: Application
    Filed: October 1, 2008
    Publication date: April 1, 2010
    Inventors: Douglas A. McCarville, Juan C. Guzman, Michael L. Hand, Michael J. Robinson
  • JOINING CURVED COMPOSITE SANDWICH PANELS
    Publication number: 20100080942
    Abstract: A curved composite structure, comprises at least two curved composite panel segments joined together. Each of the panel segments includes a fluted core sandwiched between first and second facesheets. A layer of adhesive is used to rigidly bond the panel segments together.
    Type: Application
    Filed: March 4, 2009
    Publication date: April 1, 2010
    Inventors: Douglas A. McCarville, Juan C. Guzman
  • METHOD FOR PRODUCING CONTOURED COMPOSITE STRUCTURES AND STRUCTURES PRODUCED THEREBY
    Publication number: 20090261199
    Abstract: A method is provided for forming a composite part contoured along its length and having at least one leg. The method includes forming a stack of fiber reinforced, pre-preg plies by laying down individual segments of unidirectional fibers in each ply. Each of the segments is placed in a preselected orientation related to the contour of the part. The leg is formed by bending a portion of the stack over a tool.
    Type: Application
    Filed: April 17, 2008
    Publication date: October 22, 2009
    Inventors: Douglas A. McCarville, Patrick B. Stickler, Juan C. Guzman, Jennifer S. Noel, Joseph L. Sweetin
  • METHOD FOR PRODUCING CONTOURED COMPOSITE STRUCTURES AND STRUCTURES PRODUCED THEREBY
    Publication number: 20090263618
    Abstract: A contoured composite structure is fabricated by laying up a composite charge that includes at least one ply formed by uni-directional fiber pre-preg ply segments having substantially constant widths. The ply segments are placed in side-by-side, overlapping relationship with their longitudinal centerlines aligned in a polar orientation related to the contour of the structure. The charge is formed into the shape of the structure and cured.
    Type: Application
    Filed: March 2, 2009
    Publication date: October 22, 2009
    Inventors: Douglas A. McCarville, Joseph L. Sweetin, Juan C. Guzman
  • FOAM STIFFENED HOLLOW COMPOSITE STRINGER
    Publication number: 20090127393
    Abstract: A method and apparatus for a composite stringer. A method is used for manufacturing a hollow composite stringer. Foam is formed with a mandrel installed into the foam. A composite material and the foam is laid up onto a tool in a form of a stringer. The composite material and the foam in the form of the stringer is cured to form a cured stringer. The mandrel from the foam is removed to form the hollow composite stringer.
    Type: Application
    Filed: November 8, 2007
    Publication date: May 21, 2009
    Inventors: Juan C. Guzman, Douglas A. McCarville, Daniel M. Rotter, Barry P. VanWest
  • SHAPED COMPOSITE STRINGERS AND METHODS OF MAKING
    Publication number: 20080290214
    Abstract: A stiffened skin panel of an aircraft that includes an aircraft skin panel of composite material and a composite stringer consolidated with the aircraft skin panel. The stringer has a pair of stringer sides, each extending from a stringer top to a stringer leg. The stringer sides may each extend through a wide radius, smooth continuous curve to a stringer leg. The wide radius, smooth continuous curve may be proximate the base of the stringer side in a region where the stringer side transitions to the stringer leg.
    Type: Application
    Filed: May 24, 2007
    Publication date: November 27, 2008
    Inventors: Juan C. Guzman, Douglas A. McCarville, Daniel M. Rotter, Brian G. Robins
  • Resistance welding of thermoplastics in aerospace structure
    Patent number: 7126096
    Abstract: Rib and spar webs are joined in a composite wingbox to eliminate fasteners by welding the webs along bondlines defined by overlapping sections of the webs. Heat to produce the weld is generally achieved resistively by connecting a multistrip susceptor positioned along the bond line to a current source, since the geometry makes it difficult to heat these web joints inductively. The wingbox is completed without fasteners by welding skins to the rib-spar wingbox.
    Type: Grant
    Filed: June 6, 1995
    Date of Patent: October 24, 2006
    Assignee: Th Boeing Company
    Inventors: Marc R. Matsen, Douglas A. McCarville, Michael M. Stepan