Patents by Inventor Douglas Melton Carper
Douglas Melton Carper 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: 11702948Abstract: A shroud segment including a forward radial wall, an aft radial wall and at least one interlocking subcomponent. The forward radial wall, an aft radial wall and the at least one interlocking subcomponent are each formed of a ceramic matrix composite (CMC) including reinforcing fibers embedded in a matrix. The shroud segment further including an interlocking mechanical joint joining each of the forward radial wall and the aft radial wall to the at least one interlocking subcomponent. Methods are also provided for joining the forward radial wall and the aft radial wall to the at least one interlocking subcomponent using an interlocking mechanical joint.Type: GrantFiled: November 1, 2021Date of Patent: July 18, 2023Assignee: General Electric CompanyInventors: Mackenzie Christopher Hock, Daniel Gene Dunn, Douglas Glenn Decesare, Douglas Melton Carper, Steven Robert Hayashi, Nathan Carl Sizemore, Nolan Leander Cousineau
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Patent number: 11466580Abstract: A nozzle including a vane and a band, each having defined therein interlocking features. The vane and the band are each formed of a ceramic matrix composite (CMC) including reinforcing fibers embedded in a matrix. The vane and the band include one or more interlocking features. The nozzle further including an interlocking mechanical joint joining the vane and the band to one another. Methods are also provided for joining the vane and the band at the interlocking features to form an interlocking mechanical joint.Type: GrantFiled: May 2, 2018Date of Patent: October 11, 2022Assignee: General Electric CompanyInventors: Sara Saxton Underwood, Douglas Glenn Decesare, Michael Ray Tuertscher, Daniel Gene Dunn, Douglas Melton Carper
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Publication number: 20220056809Abstract: A shroud segment including a forward radial wall, an aft radial wall and at least one interlocking subcomponent. The forward radial wall, an aft radial wall and the at least one interlocking subcomponent are each formed of a ceramic matrix composite (CMC) including reinforcing fibers embedded in a matrix. The shroud segment further including an interlocking mechanical joint joining each of the forward radial wall and the aft radial wall to the at least one interlocking subcomponent. Methods are also provided for joining the forward radial wall and the aft radial wall to the at least one interlocking subcomponent using an interlocking mechanical joint.Type: ApplicationFiled: November 1, 2021Publication date: February 24, 2022Inventors: Mackenzie Christopher Hock, Daniel Gene Dunn, Douglas Glenn Decesare, Douglas Melton Carper, Steven Robert Hayashi, Nathan Carl Sizemore, Nolan Leander Cousineau
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Patent number: 10738628Abstract: A ceramic matrix composite (CMC) component including a subcomponent, such as a band flowpath, a load bearing wall and a wall support, each comprised of a ceramic matrix composite (CMC) including reinforcing fibers embedded in a matrix. The CMC component further including at least one mechanical joint joining the subcomponent, the load bearing wall and the wall support to form the CMC component. The reinforcing fibers of the load bearing wall are oriented substantially normal to the reinforcing fibers of the subcomponent and the wall support. Methods are also provided for joining the subcomponent, the load bearing wall and the wall support to form a mechanical joint.Type: GrantFiled: May 25, 2018Date of Patent: August 11, 2020Assignee: GENERAL ELECTRIC COMPANYInventors: Sara Saxton Underwood, Douglas Glenn Decesare, Michael Ray Tuertscher, Daniel Gene Dunn, Douglas Melton Carper, Brian Gregg Feie
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Publication number: 20190360346Abstract: A ceramic matrix composite (CMC) component including a subcomponent, such as a band flowpath, a load bearing wall and a wall support, each comprised of a ceramic matrix composite (CMC) including reinforcing fibers embedded in a matrix. The CMC component further including at least one mechanical joint joining the subcomponent, the load bearing wall and the wall support to form the CMC component. The reinforcing fibers of the load bearing wall are oriented substantially normal to the reinforcing fibers of the subcomponent and the wall support. Methods are also provided for joining the subcomponent, the load bearing wall and the wall support to form a mechanical joint.Type: ApplicationFiled: May 25, 2018Publication date: November 28, 2019Inventors: Sara Saxton Underwood, Douglas Glenn Decesare, Michael Ray Tuertscher, Daniel Gene Dunn, Douglas Melton Carper, Brian Gregg Feie
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Publication number: 20190338660Abstract: A nozzle including a vane and a band, each having defined therein interlocking features. The vane and the band are each formed of a ceramic matrix composite (CMC) including reinforcing fibers embedded in a matrix. The vane and the band include one or more interlocking features. The nozzle further including an interlocking mechanical joint joining the vane and the band to one another. Methods are also provided for joining the vane and the band at the interlocking features to form an interlocking mechanical joint.Type: ApplicationFiled: May 2, 2018Publication date: November 7, 2019Inventors: Sara Saxton Underwood, Douglas Glenn Decesare, Michael Ray Tuertscher, Daniel Gene Dunn, Douglas Melton Carper
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Publication number: 20190284947Abstract: A shroud segment including a forward radial wall, an aft radial wall and at least one interlocking subcomponent. The forward radial wall, an aft radial wall and the at least one interlocking subcomponent are each formed of a ceramic matrix composite (CMC) including reinforcing fibers embedded in a matrix. The shroud segment further including an interlocking mechanical joint joining each of the forward radial wall and the aft radial wall to the at least one interlocking subcomponent. Methods are also provided for joining the forward radial wall and the aft radial wall to the at least one interlocking subcomponent using an interlocking mechanical joint.Type: ApplicationFiled: March 14, 2018Publication date: September 19, 2019Inventors: Mackenzie Christopher Hock, Daniel Gene Dunn, Douglas Glenn Decesare, Douglas Melton Carper, Steven Robert Hayashi, Nathan Carl Sizemore, Nolan Leander Cousineau
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Patent number: 9005382Abstract: A method for forming a ceramic matrix composite (CMC) component for gas turbine engines. The method contemplates replacing a plurality of plies with insert material. The insert material can be partially cured or pre-cured and applied in place of a plurality of small plies or it may be inserted into cavities of a component in the form of a paste or a ply. The insert material is isotropic, being formed of a combination of matrix material and chopped fibers, tow, cut plies or combinations thereof. The use of the insert material allows for features such as thin edges (650) with thicknesses of less than about 0.030 inches and small radii such as found in corners (680, 710). The CMC components of the present invention replace small ply inserts cut to size to fit into areas of contour change or thickness change, and replace the small ply inserts with a fabricated single piece discontinuously reinforced composite insert, resulting in fewer defects, such as wrinkles, and better dimensional control.Type: GrantFiled: September 4, 2009Date of Patent: April 14, 2015Assignee: General Electric CompanyInventors: James Dale Steibel, Douglas Melton Carper, Suresh Subramanian, Stephen Mark Whiteker
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Patent number: 8663778Abstract: A three-dimensional preform, composite components formed with the preform, and processes for producing the preform and composite materials. The three-dimensional preform includes first and second sets of tows containing filaments. Each tow of the first set has a predetermined polygonal cross-sectional shape and is embedded within a temporary matrix. The preform is fabricated from the first and second sets of tows, in which the second set of tows are transverse to the first set of tows, adjacent tows of the second set are spaced apart to define interstitial regions therebetween, and the polygonal cross-sectional shapes of the first set of tows are substantially congruent to the cross-sectional shapes of the interstitial regions so as to substantially fill the interstitial regions.Type: GrantFiled: October 15, 2010Date of Patent: March 4, 2014Assignee: General Electric CompanyInventors: Timothy Daniel Kostar, Douglas Melton Carper, Suresh Subramanian, James Dale Steible
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Publication number: 20110229337Abstract: The present invention is a hybrid ceramic matrix composite turbine engine component comprising an outer shell section(s) and an inner core section(s), wherein the outer shell section(s) and the inner core section(s) were bonded together using a melt infiltration (MI) process. The outer shell section(s) comprises a SiC/SiC material that has been manufactured using a process selected from the group consisting of a slurry cast MI process and a prepreg MI process. The inner core section(s) comprises a material selected from the group consisting an Si/SiC composite material and a monolithic ceramic material. The Si/SiC composite material may be manufactured using the Silcomp process. The present invention may be a high pressure turbine blade, a high pressure turbine vane, a low pressure turbine blade, or a low pressure turbine vane. The present invention is also a method of manufacturing a hybrid ceramic matrix composite turbine engine component.Type: ApplicationFiled: June 30, 2010Publication date: September 22, 2011Applicant: GENERAL ELECTRIC COMPANYInventors: Douglas Melton Carper, Suresh Subramanian, Richard William Jendrix, James Dale Steibel
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Publication number: 20110215502Abstract: The integral layer provides a ductile interface for attachment locations of a turbine engine component where a metallic surface is adjacent the attachment location. The ductile layer provides a favorable load distribution through the composite at the attachment location, and eliminates the need for a metallic shim.Type: ApplicationFiled: March 3, 2011Publication date: September 8, 2011Applicant: GENERAL ELECTRIC COMPANYInventors: Douglas Melton CARPER, Suresh SUBRAMANIAN
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Patent number: 7968031Abstract: The integral layer provides a ductile interface for attachment locations of a turbine engine component where a metallic surface is adjacent the attachment location. The ductile layer provides a favorable load distribution through the composite at the attachment location, and eliminates the need for a metallic shim.Type: GrantFiled: November 12, 2007Date of Patent: June 28, 2011Assignee: General Electric CompanyInventors: Douglas Melton Carper, Suresh Sabramanian
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Publication number: 20110027525Abstract: A three-dimensional preform, composite components formed with the preform, and processes for producing the preform and composite materials. The three-dimensional preform includes first and second sets of tows containing filaments. Each tow of the first set has a predetermined polygonal cross-sectional shape and is embedded within a temporary matrix. The preform is fabricated from the first and second sets of tows, in which the second set of tows are transverse to the first set of tows, adjacent tows of the second set are spaced apart to define interstitial regions therebetween, and the polygonal cross-sectional shapes of the first set of tows are substantially congruent to the cross-sectional shapes of the interstitial regions so as to substantially fill the interstitial regions.Type: ApplicationFiled: October 15, 2010Publication date: February 3, 2011Applicant: GENERAL ELECTRIC COMPANYInventors: Timothy Daniel Kostar, Douglas Melton Carper, Suresh Subramanian, James Dale Steibel
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Patent number: 7837914Abstract: A preform architecture and process for producing composite materials, and particularly CMC components. The process entails producing a composite component having a matrix material reinforced with a three-dimensional preform. The process includes producing first and second sets of tows containing filaments. Each tow of the first set has a predetermined cross-sectional shape and is embedded within a temporary matrix material formed of a material that is not the matrix material or a precursor of the matrix material. The preform is then fabricated from the first and second sets of tows, in which the second set of tows are transverse to the first set of tows, adjacent tows of the second set are spaced apart to define interstitial regions therebetween, and the cross-sectional shapes of the first set of tows are substantially congruent to the cross-sectional shapes of the interstitial regions so as to substantially fill the interstitial regions.Type: GrantFiled: December 4, 2006Date of Patent: November 23, 2010Assignee: General Electric CompanyInventors: Timothy Daniel Kostar, Douglas Melton Carper, Suresh Subramanian, James Dale Steibel
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Patent number: 7754126Abstract: A method of manufacturing a turbine engine component is disclosed. The method includes the steps of providing a plurality of ceramic cloth plies, each ply having woven ceramic fiber tows and at least one fugitive fiber tow, laying up the plurality of plies in a preselected arrangement to form a turbine engine component shape, oxidizing the fugitive fibers to produce fugitive fiber void regions in the ply, rigidizing the component shape to form a coated component preform using chemical vapor infiltration, partially densifying the coated component preform using carbon-containing slurry, and further densifying the coated component preform with at least silicon to form a ceramic matrix composite turbine engine component having matrix rich regions.Type: GrantFiled: June 17, 2005Date of Patent: July 13, 2010Assignee: General Electric CompanyInventors: Suresh Subramanian, James Dale Steibel, Douglas Melton Carper
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Publication number: 20090324878Abstract: A ceramic matrix composite (CMC) component for gas turbine engines, the component having fine features such as thin edges with thicknesses of less than about 0.030 inches and small radii of less that about 0.030 inches formed using the combination of prepreg plies layed up with non-ply ceramic inserts. The CMC components of the present invention replace small ply inserts cut to size to fit into areas of contour change or thickness change, and replace the small ply inserts with a fabricated single piece discontinuously reinforced composite insert, resulting in fewer defects, such as wrinkles, and better dimensional control.Type: ApplicationFiled: September 4, 2009Publication date: December 31, 2009Applicant: GENERAL ELECTRIC COMPANYInventors: James Dale STEIBEL, Douglas Melton CARPER, Suresh SUBRAMANIAN, Stephen Mark WHITEKER
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Publication number: 20090317612Abstract: A ceramic matrix composite with a ceramic matrix and a gradient layering of coating on ceramic fibers. The coating typically improves the performance of the composite in one direction while degrading it in another direction. For a SiC-SiC ceramic matrix composite, a BN coating is layered in a gradient fashion or in a step-wise fashion in different regions of the article comprising the ceramic. The BN coating thickness is applied over the ceramic fibers to produce varying desired physical properties by varying the coating thickness within differing regions of the composite, thereby tailoring the strength of the composite in the different regions. The coating may be applied as a single layer as a multi-layer coating to enhance the performance of the coating as the ceramic matrix is formed or infiltrated from precursor materials into a preform of the ceramic fibers.Type: ApplicationFiled: August 25, 2009Publication date: December 24, 2009Applicant: GENERAL ELECTRIC COMPANYInventors: Suresh SUBRAMANIAN, James Dale STEIBEL, Douglas Melton CARPER, Toby George DARKINS, JR.
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Patent number: 7600979Abstract: A ceramic matrix composite (CMC) component for gas turbine engines, the component having fine features such as thin edges with thicknesses of less than about 0.030 inches and small radii of less that about 0.030 inches formed using the combination of prepreg plies layed up with non-ply ceramic inserts. The CMC components of the present invention replace small ply inserts cut to size to fit into areas of contour change or thickness change, and replace the small ply inserts with a fabricated single piece discontinuously reinforced composite insert, resulting in fewer defects, such as wrinkles, and better dimensional control.Type: GrantFiled: November 28, 2006Date of Patent: October 13, 2009Assignee: General Electric CompanyInventors: James Dale Steibel, Douglas Melton Carper, Suresh Subramanian, Stephen Mark Whiteker
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Patent number: 7597838Abstract: A ceramic matrix composite with a ceramic matrix and a gradient layering of coating on ceramic fibers. The coating typically improves the performance of the composite in one direction while degrading it in another direction. For a SiC-SiC ceramic matrix composite, a BN coating is layered in a gradient fashion or in a step-wise fashion in different regions of the article comprising the ceramic. The BN coating thickness is applied over the ceramic fibers to produce varying desired physical properties by varying the coating thickness within differing regions of the composite, thereby tailoring the strength of the composite in the different regions. The coating may be applied as a single layer as a multi-layer coating to enhance the performance of the coating as the ceramic matrix is formed or infiltrated from precursor materials into a preform of the ceramic fibers.Type: GrantFiled: December 30, 2004Date of Patent: October 6, 2009Assignee: General Electric CompanyInventors: Suresh Subramanian, James Dale Steibel, Douglas Melton Carper, Toby George Darkins, Jr.
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Patent number: 7579094Abstract: The present invention is a ceramic matrix composite turbine engine component, wherein the component has a direction of maximum tensile stress during normal engine operation. The component comprises a plurality of biased ceramic plies, wherein each biased ply comprises ceramic fiber tows, the tows being woven in a first warp direction and a second weft direction, the second weft direction lying at a preselected angular orientation with respect to the first warp direction, wherein a greater number of tows are woven in the first warp direction than in the second weft direction, and wherein a number of tows in the second weft direction allows the biased plies to maintain their structural integrity when handled.Type: GrantFiled: June 16, 2006Date of Patent: August 25, 2009Assignee: General Electric CompanyInventors: Suresh Subramanian, James Dale Steibel, Douglas Melton Carper, Brian Keith Flandermeyer