Patents by Inventor Eric C. Clough

Eric C. Clough 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: 12343798
    Abstract: A multi-material structure includes a refractory portion with a metal or metal alloy of at least one of niobium (Nb), molybdenum (Mo), tantalum (Ta), tungsten (W), rhenium (Re), iridium (Ir), vanadium (V), and ruthenium (Ru). A structural portion is metallurgically joined with the refractory portion. The structural portion includes a titanium (Ti) alloy. At least one of the refractory and structural portions is additively manufactured.
    Type: Grant
    Filed: March 6, 2023
    Date of Patent: July 1, 2025
    Assignee: The Boeing Company
    Inventors: Jonathan D. Embler, William E. O'Connor, Tobias Schaedler, Eric C. Clough, Raymond Nguyen, Sonia Zacher
  • Publication number: 20250158465
    Abstract: A radial flux electric motor includes a stator having a radially inner stator surface and stator windings arranged thereon. The motor also includes a rotor mounted inside the stator and configured to rotate relative thereto about an axis. The rotor has a rotor core constructed from a ferromagnetic material having relatively high magnetic permeability and defined by a rotor outer surface establishing an airgap between the rotor and the stator. The rotor also has a plurality of magnetic poles set in the rotor core and configured to generate magnetic flux. The rotor additionally has inserts constructed from a material having relatively low magnetic permeability in at least one geometric direction. Each insert is mechanically fixed to the rotor core to thereby control magnetic flux distribution and minimize flux leakage inside the rotor.
    Type: Application
    Filed: November 15, 2023
    Publication date: May 15, 2025
    Applicant: GM Global Technology Operations LLC
    Inventors: Alireza Fatemi, Eric C. Clough, Thomas W. Nehl, Wesley G. Zanardelli, David A. Smith
  • Publication number: 20250158464
    Abstract: A radial flux electric motor includes a stator having a radially inner stator surface and stator windings arranged thereon. The motor also includes a rotor mounted inside the stator and configured to rotate relative thereto about an axis. The rotor has a rotor core defined by a rotor outer surface and includes magnetic poles configured to generate magnetic flux and defining flux leakage zones. The motor additionally includes a selective permeability sleeve arranged circumferentially on the rotor and fixed to the rotor outer surface, thereby establishing an airgap between the sleeve and the stator. The sleeve provides reinforcement to the rotor core and to the magnetic poles and includes regions of relatively high and relatively low magnetic permeability alternating around the rotor outer surface. The regions of relatively low magnetic permeability are arranged radially outward and across from the flux leakage zones to control magnetic flux distribution in the motor.
    Type: Application
    Filed: November 15, 2023
    Publication date: May 15, 2025
    Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
    Inventors: Eric C Clough, Alireza Fatemi, Thomas W Nehl, David A. Smith
  • Patent number: 12206288
    Abstract: An electric machine may have a stator and a rotor including stacked plurality of electrical steel laminations forming a slot including a first end and opposing sides, the first end defined by a bridge extending between electrical steel on opposing sides of the slot, the bridge being located between the first end of the slot and an outer diameter surface of the rotor and beneath the outer diameter surface of the rotor, the bridge forming a base of a channel open at an outer diameter surface of the rotor.
    Type: Grant
    Filed: August 9, 2022
    Date of Patent: January 21, 2025
    Assignee: GM GLOBAL TECHNOLOGY OPERATIONS LLC
    Inventors: Alireza Fatemi, Huaxin Li, Yucong Wang, Eric C. Clough, Jonathan Watson
  • Publication number: 20240055919
    Abstract: An electric machine may have a stator and a rotor including stacked plurality of electrical steel laminations forming a slot including a first end and opposing sides, the first end defined by a bridge extending between electrical steel on opposing sides of the slot, the bridge being located between the first end of the slot and an outer diameter surface of the rotor and beneath the outer diameter surface of the rotor, the bridge forming a base of a channel open at an outer diameter surface of the rotor.
    Type: Application
    Filed: August 9, 2022
    Publication date: February 15, 2024
    Inventors: Alireza Fatemi, Huaxin Li, Yucong Wang, Eric C. Clough, Jonathan Watson
  • Publication number: 20230415236
    Abstract: A multi-material structure includes a refractory portion with a metal or metal alloy of at least one of niobium (Nb), molybdenum (Mo), tantalum (Ta), tungsten (W), rhenium (Re), iridium (Ir), vanadium (V), and ruthenium (Ru). A structural portion is metallurgically joined with the refractory portion. The structural portion includes a titanium (Ti) alloy. At least one of the refractory and structural portions is additively manufactured.
    Type: Application
    Filed: March 6, 2023
    Publication date: December 28, 2023
    Applicant: The Boeing Company
    Inventors: Jonathan D. Embler, William E. O'Connor, Tobias Schaedler, Eric C. Clough, Raymond Nguyen, Sonia Zacher
  • Patent number: 11806956
    Abstract: A method of repairing a sandwich structure includes: removing a damaged portion of a core and a damaged portion of a first facesheet to form an open volume; filling the open volume with an ultraviolet-curable photomonomer; partially curing the ultraviolet-curable photomonomer to form a plurality of photopolymer waveguides by utilizing ultraviolet light; and arranging a replacement facesheet on the damaged portion of the first facesheet and over the photopolymer waveguides.
    Type: Grant
    Filed: July 9, 2021
    Date of Patent: November 7, 2023
    Assignee: HRL LABORATORIES, LLC
    Inventors: Jacob M. Hundley, Eric C. Clough, Zak C. Eckel, David Page, Sophia S. Yang
  • Patent number: 11584505
    Abstract: A phononic composite material providing structural strength and blocking the propagation of elastic waves over a frequency range referred to as the bandgap. In one embodiment, the phononic composite material consists of a plurality of periodic units, each of which includes a central fiber, a relatively soft interface layer surrounding the fiber, and a matrix layer surrounding the interface layer. The properties of the interface layer may be adjusted, e.g., by adjusting the temperature of the phononic composite material, to transition from a state with a bandgap to a state lacking a bandgap.
    Type: Grant
    Filed: February 5, 2019
    Date of Patent: February 21, 2023
    Assignee: HRL LABORATORIES, LLC
    Inventors: Jacob M. Hundley, Eric C. Clough, Alan J. Jacobsen
  • Publication number: 20220234315
    Abstract: A method of forming a sandwich structure including at least partially filling an open volume of an open cellular core with a sacrificial mold material, consolidating the sacrificial mold material to form a sacrificial mold, laying up a composite facesheet on each of at least two surfaces of the open cellular core, co-curing the composite facesheets by applying a consolidation temperature and a compaction pressure to the composite facesheets to form the sandwich structure, and removing the sacrificial mold. The compaction pressure is greater than a compressive strength of the open cellular core and less than a combined compressive strength of the open cellular core and the sacrificial mold.
    Type: Application
    Filed: April 12, 2022
    Publication date: July 28, 2022
    Inventors: Jacob M. Hundley, Alicia J. Dias, Eric C. Clough, Tobias A. Schaedler
  • Patent number: 11358350
    Abstract: A method of forming a sandwich structure including at least partially filling an open volume of an open cellular core with a sacrificial mold material, consolidating the sacrificial mold material to form a sacrificial mold, laying up a composite facesheet on each of at least two surfaces of the open cellular core, co-curing the composite facesheets by applying a consolidation temperature and a compaction pressure to the composite facesheets to form the sandwich structure, and removing the sacrificial mold. The compaction pressure is greater than a compressive strength of the open cellular core and less than a combined compressive strength of the open cellular core and the sacrificial mold.
    Type: Grant
    Filed: April 30, 2018
    Date of Patent: June 14, 2022
    Assignee: HRL Laboratories, LLC
    Inventors: Jacob M. Hundley, Alicia J. Dias, Eric C. Clough, Tobias A. Schaedler
  • Patent number: 11167455
    Abstract: A system for fabricating composite parts efficiently. Pre-impregnated (prepreg) composite material is drawn as a sheet from a roll and fed by advancement rollers into a stamping and molding station in which a piece of the prepreg material is cut, on a mold, from the sheet. Pressure is applied to cause the prepreg material to conform to a surface of the mold, and the prepreg is cured with ultraviolet light. Additional layers of prepreg may be cut and cured on any layers that have already been cured on the mold. The complete part may be removed from the mold with ejector pins. Scrap prepreg may be recycled in a recycling station that separates reinforcing fiber from uncured resin.
    Type: Grant
    Filed: June 19, 2020
    Date of Patent: November 9, 2021
    Assignee: HRL Laboratories, LLC
    Inventors: Jacob M. Hundley, Eric C. Clough, Zak C. Eckel
  • Patent number: 11155681
    Abstract: A composition for forming a microlattice structure includes a photopolymerizable compound and a flame retardant material. A microlattice structure includes a plurality of struts interconnected at a plurality of nodes, the struts including: a copolymer including a reaction product of a photopolymerizable compound and a flame retardant material. A microlattice structure includes a plurality of struts interconnected at a plurality of nodes, the struts including: a polymer including a reaction product of a photopolymerizable compound; and a flame retardant material.
    Type: Grant
    Filed: July 22, 2019
    Date of Patent: October 26, 2021
    Assignee: HRL Laboratories, LLC
    Inventors: Sophia S. Yang, Eric C. Clough, Thomas I. Boundy, Andrew P. Nowak, Zak C. Eckel, Alan J. Jacobsen
  • Patent number: 11148375
    Abstract: A method of repairing a sandwich structure includes: removing a damaged portion of a core and a damaged portion of a first facesheet to form an open volume; filling the open volume with an ultraviolet-curable photomonomer; partially curing the ultraviolet-curable photomonomer to form a plurality of photopolymer waveguides by utilizing ultraviolet light; and arranging a replacement facesheet on the damaged portion of the first facesheet and over the photopolymer waveguides.
    Type: Grant
    Filed: October 16, 2019
    Date of Patent: October 19, 2021
    Assignee: HRL Laboratories, LLC
    Inventors: Jacob M. Hundley, Eric C. Clough, Zak C. Eckel, David Page, Sophia S. Yang
  • Patent number: 10974995
    Abstract: A method for fabricating a ceramic matrix composite structure. A core having an ordered structure is fabricated of a preceramic polymer and pyrolyzed. Facesheets, either uncured or cured, are placed on the core (with a bonding layer of preceramic polymer resin if the facesheets are cured) and the assembly is cured and pyrolyzed. The pyrolyzed assembly is re-infiltrated with preceramic polymer resin and re-pyrolyzed. The cycle of re-infiltration and re-pyrolyzation is repeated until the mass gain per cycle stabilizes.
    Type: Grant
    Filed: July 6, 2017
    Date of Patent: April 13, 2021
    Assignee: HRL Laboratories, LLC
    Inventors: Christine M. Lihn, Jacob M. Hundley, Tobias A. Schaedler, Eric C. Clough, Kenneth Cante
  • Patent number: 10946600
    Abstract: A method for repairing a composite structure. A damaged portion of a first facesheet of the structure is removed, forming a hole in the first facesheet. A damaged portion of the underlying core is removed to form a cavity in the sandwich. If the second facesheet is damaged, the damaged section is removed, and covered and sealed with a facesheet repair section. If the core material is an open-cell material, a dam is formed around the perimeter of the cavity, to act as a barrier between the cavity and the core material. The cavity is at least partially filled with a photomonomer resin, which then is illuminated through a mask with collimated light to form a truss structure in the cavity. Residual photomonomer resin is removed, and a facesheet repair section is bonded over the hole in the first facesheet.
    Type: Grant
    Filed: August 29, 2017
    Date of Patent: March 16, 2021
    Assignee: HRL Laboratories, LLC
    Inventors: Jacob M. Hundley, Eric C. Clough, Zak C. Eckel, David Page, Sophia S. Yang
  • Patent number: 10942010
    Abstract: According to an embodiment of the present invention, a three-dimensional architected armor structure includes a core structure and a matrix. The core structure includes: a plurality of impact members; a plurality of joint members below the impact members; and a plurality of connection members respectively extending between one of the impact members and one of the joint members. The matrix fills at least a portion of a space between the impact members, the joint members, and the connection members.
    Type: Grant
    Filed: May 23, 2018
    Date of Patent: March 9, 2021
    Assignee: HRL Laboratories, LLC
    Inventors: John H. Martin, Brennon D. Yahata, Robert W. Cumberland, Jacob M. Hundley, Robert Mone, Eric C. Clough
  • Patent number: 10894748
    Abstract: A method of manufacturing an ordered cellular structure including a series of interconnected unit cells. Each unit cell includes at least one straight wall segment. The method includes irradiating a volume of photo-monomer in a reservoir with at least one light beam from at least one light source to form the ordered cellular structure. Irradiating the volume of photo-monomer includes directing the at least one light beam though a series of interconnected apertures defined in a photo-mask covering the reservoir.
    Type: Grant
    Filed: July 12, 2019
    Date of Patent: January 19, 2021
    Assignee: HRL Laboratories, LLC
    Inventors: Zak C. Eckel, Tobias A. Schaedler, Eric C. Clough
  • Patent number: 10882220
    Abstract: A method and/or system for forming a micro-truss structure in an essentially arbitrary shape. A mold that has a transparent portion, and having an interior volume in the desired shape, is filled with photomonomer resin. The material for the transparent portion of the mold is selected to be a material that is index-matched to the photomonomer resin. The filled mold, placed into a bath of transparent fluid index-matched to the transparent portion of the mold, and illuminated, from outside the fluid, through a photomask, with collimated light. The collimated light travels through the photomask forming beams of light that enter the transparent fluid, propagate into the mold, and form a micro-truss structure in the shape of the interior volume of the mold. The micro-truss structure may then be removed from the mold, or part or all of the mold may be left adhered to the micro-truss structure, forming covering face sheets.
    Type: Grant
    Filed: January 24, 2019
    Date of Patent: January 5, 2021
    Assignee: HRL Laboratories, LLC
    Inventors: Jie Ensberg, Christopher J. Ro, Sophia S. Yang, Zak C. Eckel, Eric C. Clough
  • Patent number: 10737411
    Abstract: A system for fabricating composite parts efficiently. Pre-impregnated (prepreg) composite material is drawn as a sheet from a roll and fed by advancement rollers into a stamping and molding station in which a piece of the prepreg material is cut, on a mold, from the sheet. Pressure is applied to cause the prepreg material to conform to a surface of the mold, and the prepreg is cured with ultraviolet light. Additional layers of prepreg may be cut and cured on any layers that have already been cured on the mold. The complete part may be removed from the mold with ejector pins. Scrap prepreg may be recycled in a recycling station that separates reinforcing fiber from uncured resin.
    Type: Grant
    Filed: April 29, 2016
    Date of Patent: August 11, 2020
    Assignee: HRL Laboratories, LLC
    Inventors: Jacob M. Hundley, Eric C. Clough, Zak C. Eckel
  • Patent number: 10500811
    Abstract: A lightweight sandwich panel structure with a complex shape and curvature, and a method to fabricate such a panel out of high temperature alloys. Embodiments of a micro-truss core structure that offer high specific strength and stiffness while allowing for curvature, and methods for depositing multiple layers of metals that can be interdiffused into complex alloys, are provided. A core of a panel may be fabricated from a polymer template, which may be shaped, e.g., curved, and coated with metal layers, which may then be heat treated to cause the layers of metal to interdiffuse, to form an alloy.
    Type: Grant
    Filed: April 20, 2017
    Date of Patent: December 10, 2019
    Assignee: HRL Laboratories, LLC
    Inventors: Tobias A. Schaedler, Jacob M. Hundley, John H. Martin, Christopher S. Roper, Eric C. Clough