Patents by Inventor Dwight L. Engwall

Dwight L. Engwall 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).

  • Patent number: 8844599
    Abstract: Configurable layup tooling used to fabricate reinforced composite parts having a common shape but varying features are disclosed herein. An example apparatus disclosed herein includes a common tool body. A first mandrel is received by the common tool body to form at least a first portion of a common shape and a first profile of a first part to be formed via the common tool body. A second mandrel is received by the common tool body to form the first portion of the common shape and a second profile of a second part that is different from the first part.
    Type: Grant
    Filed: November 21, 2012
    Date of Patent: September 30, 2014
    Assignee: The Boeing Company
    Inventors: Mark A. Schmier, II, Dwight L. Engwall, Carlos Pena
  • Patent number: 8337654
    Abstract: Configurable layup tooling is used to fabricate reinforced composite parts have a common shape but varying features. The tooling includes a tool base, multiple mandrels and optionally, a tool insert, all of which may be used to form a portion of the common shape. The mandrels have differing tool geometries for forming the varying features of the commonly shaped parts. The tool base may be used as a bonding jig to assemble and bond assemblies that include the fabricated parts.
    Type: Grant
    Filed: May 11, 2007
    Date of Patent: December 25, 2012
    Assignee: The Boeing Company
    Inventors: Mark A. Schmier, II, Dwight L. Engwall, Carlos Pena
  • Patent number: 7897004
    Abstract: A method for fabricating stringers is provided. The co-cured composite stringer includes a stringer and a mandrel positioned within a channel defined in the stringer. A plurality of strips are positioned within an opening of the mandrel, and a substrate layer, such as aircraft skin, is positioned adjacent to the stringer. During application of the substrate layer to the stringer, the mandrel and plurality of strips support the stringer.
    Type: Grant
    Filed: September 6, 2007
    Date of Patent: March 1, 2011
    Assignee: The Boeing Company
    Inventors: Dwight L. Engwall, Christopher J. Morrow
  • Patent number: 7694981
    Abstract: A mobile storage and work cart is described that includes a reconfigurable frame, a plurality of casters extending from the reconfigurable frame and operable for moving the cart, and a work surface attached to the reconfigurable frame and forming a top of the cart. The reconfigurable frame is operable to adjust a height of the work surface.
    Type: Grant
    Filed: March 20, 2007
    Date of Patent: April 13, 2010
    Assignee: The Boeing Company
    Inventors: Jonathan C. Heath, Richard R. Fengler, Stephen A. Doyle, Dwight L. Engwall, Peter K. Bilitsis, Frederick C. Edman, Gary E. Jones, Thomas G. Klingler, Richard D. Tuzzolino, Erwin R. Kuhn, Basilio Penuelas, Lawrence M. Apodaca
  • Patent number: 7530530
    Abstract: Embodiments of an assembly for securing a stringer to a substrate are provided. The stringer assembly includes a stringer and a mandrel positioned within a channel defined in the stringer. A plurality of strips are positioned within an opening of the mandrel, and a substrate layer, such as aircraft skin, is positioned adjacent to the stringer. During application of the substrate layer to the stringer, the mandrel and plurality of strips support the stringer.
    Type: Grant
    Filed: September 6, 2007
    Date of Patent: May 12, 2009
    Assignee: The Boeing Company
    Inventors: Dwight L. Engwall, Christopher J. Morrow
  • Publication number: 20080277058
    Abstract: Configurable layup tooling is used to fabricate reinforced composite parts have a common shape but varying features. The tooling includes a tool base, multiple mandrels and optionally, a tool insert, all of which may be used to form a portion of the common shape. The mandrels have differing tool geometries for forming the varying features of the commonly shaped parts. The tool base may be used as a bonding jig to assemble and bond assemblies that include the fabricated parts.
    Type: Application
    Filed: May 11, 2007
    Publication date: November 13, 2008
    Inventors: Mark A. Schmier, II, Dwight L. Engwall, Carlos Pena
  • Publication number: 20080231149
    Abstract: A mobile storage and work cart is described that includes a reconfigurable frame, a plurality of casters extending from the reconfigurable frame and operable for moving the cart, and a work surface attached to the reconfigurable frame and forming a top of the cart. The reconfigurable frame is operable to adjust a height of the work surface.
    Type: Application
    Filed: March 20, 2007
    Publication date: September 25, 2008
    Inventors: Jonathan C. Heath, Richard R. Fengler, Stephen A. Doyle, Dwight L. Engwall, Peter K. Bilitsis, Frederick C. Edman, Gary E. Jones, Thomas G. Klingler, Richard D. Tuzzolino, Erwin R. Kuhn, Basilio Penuelas, Lawrence M. Apodaca
  • Patent number: 7422647
    Abstract: An aircraft part manufacturing device for automated composite lay up includes a mandrel tool having a an interior mandrel surface that conforms to an outside mold line (OML) of a part: to be manufactured. One or more circular rings surround the mandrel and are attached to the mandrel. The circular rings rotate supported by bearings in a bearing cradle so that the mandrel rotates concentrically with the circular rings about an axis of rotation passing through the center of the circular rings. Multiple composite material delivery heads simultaneously deliver material directly to the outside mold line on the interior mandrel surface while the mandrel is rotated. A cantilever supported gantry beam supports the material delivery heads inside the interior mandrel surface. A connecting mechanism connects the material delivery heads to the gantry beam and provides motion of the material delivery heads relative to the interior mandrel surface.
    Type: Grant
    Filed: December 9, 2005
    Date of Patent: September 9, 2008
    Assignee: The Boeing Company
    Inventors: Randall R. Clark, Dwight L. Engwall, Mark G. Yonash, Jeffrey A. New
  • Publication number: 20080128549
    Abstract: Embodiments of an assembly for securing a stringer to a substrate are provided. The stringer assembly includes a stringer and a mandrel positioned within a channel defined in the stringer. A plurality of strips are positioned within an opening of the mandrel, and a substrate layer, such as aircraft skin, is positioned adjacent to the stringer. During application of the substrate layer to the stringer, the mandrel and plurality of strips support the stringer.
    Type: Application
    Filed: September 6, 2007
    Publication date: June 5, 2008
    Inventors: Dwight L. Engwall, Christopher J. Morrow
  • Publication number: 20080110563
    Abstract: A method for fabricating stringers is provided. The co-cured composite stringer includes a stringer and a mandrel positioned within a channel defined in the stringer. A plurality of strips are positioned within an opening of the mandrel, and a substrate layer, such as aircraft skin, is positioned adjacent to the stringer. During application of the substrate layer to the stringer, the mandrel and plurality of strips support the stringer.
    Type: Application
    Filed: September 6, 2007
    Publication date: May 15, 2008
    Inventors: DWIGHT L. ENGWALL, Christopher J. Morrow
  • Patent number: 7293737
    Abstract: A co-cured composite stringer and associated apparatus and method are provided. The co-cured composite stringer includes a stringer and a mandrel positioned within a channel defined in the stringer. A plurality of strips are positioned within an opening of the mandrel, and a substrate layer, such as aircraft skin, is positioned adjacent to the stringer. During application of the substrate layer to the stringer, the mandrel and plurality of strips support the stringer.
    Type: Grant
    Filed: April 20, 2004
    Date of Patent: November 13, 2007
    Assignee: The Boeing Company
    Inventors: Dwight L. Engwall, Christopher J. Morrow
  • Patent number: 7141191
    Abstract: The present invention provides a method and apparatus for use in manufacturing a composite part includes molding a composite part on a lay-up tool, machining a sacrificial portion of a first surface for securing a first hardware device with the composite part while the part is on the lay-up tool and cutting the part forming a peripheral edge while the part is on the lay-up tool. The method can further include positioning the first hardware device in contact with a machined interface of the composite part and machining the part including drilling a plurality of positioning holes through the hardware device and the part while the part is on the lay-up tool. The machining can include machining the sacrificial portion creating a machined interface and positioning the hardware device on the machined interface.
    Type: Grant
    Filed: May 2, 2003
    Date of Patent: November 28, 2006
    Assignee: The Boeing Company
    Inventors: Dwight L. Engwall, John F. Costello
  • Patent number: 7083698
    Abstract: An aircraft part manufacturing device for automated composite lay up includes a mandrel tool having a an interior mandrel surface that conforms to an outside mold line (OML) of a part: to be manufactured. One or more circular rings surround the mandrel and are attached to the mandrel. The circular rings rotate supported by bearings in a bearing cradle so that the mandrel rotates concentrically with the circular rings about an axis of rotation passing through the center of the circular rings. A composite material delivery head delivers material directly to the outside mold line on the interior mandrel surface while the mandrel is rotated. A cantilever supported gantry beam supports the material delivery head inside the interior mandrel surface. A connecting mechanism connects the material delivery head to the gantry beam and provides motion of the material delivery head relative to the interior mandrel surface.
    Type: Grant
    Filed: August 22, 2003
    Date of Patent: August 1, 2006
    Assignee: The Boeing Company
    Inventors: Dwight L. Engwall, Mark G. Yonash, Randall R. Clark, Jeffrey A. New
  • Patent number: 7048024
    Abstract: An aircraft part manufacturing device for automated composite lay up includes a mandrel tool having a an interior mandrel surface that conforms to an outside mold line (OML) of a part: to be manufactured. One or more circular rings surround the mandrel and are attached to the mandrel. The circular rings rotate supported by bearings in a bearing cradle so that the mandrel rotates concentrically with the circular rings about an axis of rotation passing through the center of the circular rings. Multiple composite material delivery heads simultaneously deliver material directly to the outside mold line on the interior mandrel surface while the mandrel is rotated. A cantilever supported gantry beam supports the material delivery heads inside the interior mandrel surface. A connecting mechanism connects the material delivery heads to the gantry beam and provides motion of the material delivery heads relative to the interior mandrel surface.
    Type: Grant
    Filed: August 22, 2003
    Date of Patent: May 23, 2006
    Assignee: The Boeing Company
    Inventors: Randall R. Clark, Dwight L. Engwall, Mark G. Yonash, Jeffrey A. New
  • Publication number: 20040217497
    Abstract: The present invention provides a method and apparatus for use in manufacturing a composite part includes molding a composite part on a lay-up tool, machining a sacrificial portion of a first surface for securing a first hardware device with the composite part while the part is on the lay-up tool and cutting the part forming a peripheral edge while the part is on the lay-up tool. The method can further include positioning the first hardware device in contact with a machined interface of the composite part and machining the part including drilling a plurality of positioning holes through the hardware device and the part while the part is on the lay-up tool. The machining can include machining the sacrificial portion creating a machined interface and positioning the hardware device on the machined interface.
    Type: Application
    Filed: May 2, 2003
    Publication date: November 4, 2004
    Applicant: The Boeing Company
    Inventors: Dwight L. Engwall, John F. Costello
  • Patent number: 6759002
    Abstract: A method of manufacturing a composite uses a hybrid tool which serves both as a form on which constituent materials are applied for bonding or curing into a part in a desired configuration, and as a fixture for holding the bonded or cured materials in the originally applied position during subsequent machining of a peripheral edge of the part. The method includes fabricating a face sheet of composite material having a facing surface configured to the reverse of a desired shape of one surface of a part to be made on the tool. The materials for the part are applied on the face sheet, debulked, bonded or cured, and edge trimmed thereon, all while on the face sheet in the originally applied position.
    Type: Grant
    Filed: September 29, 1999
    Date of Patent: July 6, 2004
    Assignee: The Boeing Company
    Inventors: Dwight L. Engwall, Chris J. Morrow, Kevin J. Steen, Roger A. Johnson
  • Patent number: 6168358
    Abstract: A hybrid tool serves as a form on which constituent materials are applied for bonding or curing into a part in a desired configuration. It also serves as a holder for the bonded or cured materials in the originally applied position during subsequent machining. The hybrid tool is made by fabricating a face sheet of composite material having a facing surface configured to the reverse of a desired shape of one surface of a part to be made on the tool. The actual part will be laid up on the facing surface, cured while on the tool, and even trimmed before release. Base structure of the tool holds the facing surface of the face sheet in the desired shape, and includes ground-engaging pads that define an “A” datum plane. The tool aligns a reference plane of the face sheet parallel to the datum plane. A substantially continuous groove in the face sheet, used for trimming the part, opens in the facing surface.
    Type: Grant
    Filed: September 29, 1999
    Date of Patent: January 2, 2001
    Assignee: The Boeing Company
    Inventors: Dwight L. Engwall, Chris J. Morrow, Kevin J. Steen, Roger A. Johnson
  • Patent number: 6012883
    Abstract: A hybrid tool serves as a form on which constituent materials are applied for bonding or curing into a part in a desired configuration. It also serves as a holder for the bonded or cured materials in the originally applied position during subsequent machining. The hybrid tool is made by fabricating a face sheet of composite material having a facing surface configured to the reverse of a desired shape of one surface of a part to be made on the tool. The actual part will be laid up on the facing surface, cured while on the tool, and even trimmed before release. Base structure of the tool holds the facing surface of the face sheet in the desired shape, and includes ground-engaging pads that define an "A" datum plane. The tool aligns a reference plane of the face sheet parallel to the datum plane. A substantially continuous groove in the face sheet, used for trimming the part, opens in the facing surface.
    Type: Grant
    Filed: May 5, 1998
    Date of Patent: January 11, 2000
    Assignee: The Boeing Company
    Inventors: Dwight L. Engwall, Chris J. Morrow, Kevin J. Steen, Roger A. Johnson
  • Patent number: 5746553
    Abstract: A method of manufacturing a laid-up, bonded and, cured composite part, includes filling a groove on a facing surface of a tool with a foaming, self-skinning sacrificial material and covering the facing surface of the tool with a caul sheet. The tool is heated to cure the foaming material, filling the groove and forming a hard, smooth surface skin on the foam, flush with the facing surface of the tool. A series of plies are laid-up on the facing surface of the tool to form a tool-side skin, and other components of the part are laid-up on top of the tool-side skin plies. An adhesive/resin matrix is coated on or pre-impregnated into the skin plies and the components for bonding/curing to create a rigid integral assembly of the skin and components. A vacuum bag is applied over the laid-up skin and components and is sealed to peripheral regions of the facing surface of the tool around the laid-up skin and components.
    Type: Grant
    Filed: April 8, 1996
    Date of Patent: May 5, 1998
    Assignee: The Boeing Company
    Inventor: Dwight L. Engwall
  • Patent number: 5121907
    Abstract: A reconfiguration table, for holding and supporting a contoured workpiece while work is performed thereon comprising a frame defining a perimeter and a plane; a plurality of support elements disposed in spaced array within the frame perimeter, each element having an end and being independently translatable in a direction substantially perpendicular to the plane, the ends of the elements cooperating to define a support surface for the workpiece; clamp members, supported by the frame, for selectively locking the elements in position to define the support surface; attaching members, supported by the frame independently of the support elements, for holding the workpiece on the support surface; and a gear reducer and motor for rotating the frame with the workpiece supported thereon about an axis parallel to the plane of the frame.
    Type: Grant
    Filed: June 21, 1991
    Date of Patent: June 16, 1992
    Assignee: The Boeing Company
    Inventor: Dwight L. Engwall