Patents by Inventor Eric Karlen
Eric Karlen 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: 11773471Abstract: An aluminum alloy comprising greater than 2.00 and less than 4.00 wt. % cerium, 0.25-3.00 wt. % silicon, 0.25-0.75 wt. % magnesium, 0-0.75 wt. % iron, 0-0.05 wt. % other alloying elements, and the balance of aluminum, based on the total weight of the aluminum alloy aluminum alloy.Type: GrantFiled: October 15, 2021Date of Patent: October 3, 2023Assignee: HAMILTON SUNDSTRAND CORPORATIONInventors: Eric Karlen, William Louis Wentland, Sergey Mironets, Robert Bianco
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Patent number: 11618081Abstract: A method for making an article is disclosed. The method involves inputting a digital model of an article into an additive manufacturing apparatus comprising an energy source. The additive manufacturing apparatus applies energy from the energy source to successively applied incremental quantities of a powder to fuse the powder to form the article corresponding to the digital model. The powder includes an aluminum alloy having 2.00-10.00 wt. % cerium, 0.50-2.50 wt. % titanium, 0-3.00 wt. % nickel, 0-0.75 wt. % nitrogen, 0-0.05 wt. % other alloying elements, and the balance of aluminum, based on the total weight of the aluminum alloy.Type: GrantFiled: October 14, 2021Date of Patent: April 4, 2023Assignee: HAMILTON SUNDSTRAND CORPORATIONInventors: Eric Karlen, William Louis Wentland, Sergey Mironets, Robert Bianco
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Patent number: 11513080Abstract: An inspection system for an additive manufacturing machine can include a housing configured to be mounted to an internal construction of the additive manufacturing machine, wherein the housing defines a laser inlet configured to allow a laser beam from a laser of the additive manufacturing machine to enter into the housing, wherein the housing defines a laser outlet configured to allow the laser beam to exit from the housing and to allow reflected light to enter into the housing. One or more detectors is disposed within the housing and configured to receive the reflected light. The system includes one or more optical elements configured to allow the laser beam to pass through the housing from the laser inlet to the laser outlet toward a build area of the additive manufacturing machine and to direct reflected light from the laser outlet to the one or more detectors within the housing.Type: GrantFiled: September 9, 2016Date of Patent: November 29, 2022Assignee: Hamilton Sundstrand CorporationInventor: Eric Karlen
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Patent number: 11346611Abstract: A heat exchanger can include a monolithically formed body defining at least two channels configured to allow fluid to flow therethrough, at least one of the at least two channels at least partially wrapping around or within at least one other of the at least two channels. In certain embodiments, the at least two channels can include a first channel and a second channel, wherein the first channel is at least partially wound around or within the second channel.Type: GrantFiled: August 16, 2016Date of Patent: May 31, 2022Assignee: Hamilton Sundstrand CorporationInventors: William L. Wentland, Eric Karlen
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Publication number: 20220032374Abstract: A method for making an article is disclosed. The method involves inputting a digital model of an article into an additive manufacturing apparatus comprising an energy source. The additive manufacturing apparatus applies energy from the energy source to successively applied incremental quantities of a powder to fuse the powder to form the article corresponding to the digital model. The powder includes an aluminum alloy having 2.00-10.00 wt. % cerium, 0.50-2.50 wt. % titanium, 0-3.00 wt. % nickel, 0-0.75 wt. % nitrogen, 0-0.05 wt. % other alloying elements, and the balance of aluminum, based on the total weight of the aluminum alloy.Type: ApplicationFiled: October 14, 2021Publication date: February 3, 2022Inventors: Eric Karlen, William Louis Wentland, Sergey Mironets, Robert Bianco
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Publication number: 20220032375Abstract: An aluminum alloy comprising greater than 2.00 and less than 4.00 wt. % cerium, 0.25-3.00 wt. % silicon, 0.25-0.75 wt. % magnesium, 0-0.75 wt. % iron, 0-0.05 wt. % other alloying elements, and the balance of aluminum, based on the total weight of the aluminum alloy aluminum alloy.Type: ApplicationFiled: October 15, 2021Publication date: February 3, 2022Inventors: Eric Karlen, William Louis Wentland, Sergey Mironets, Robert Bianco
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Patent number: 11192188Abstract: A method for making an article is disclosed. The method involves inputting a digital model of an article into an additive manufacturing apparatus comprising an energy source. The additive manufacturing apparatus applies energy from the energy source to successively applied incremental quantities of a powder to fuse the powder to form the article corresponding to the digital model. The powder includes an aluminum alloy having 2.00-9.00 wt. % cerium, 0.25-3.00 wt. % silicon, 0.25-0.75 wt. % magnesium, 0-0.75 wt. % iron, 0-0.05 wt. % other alloying elements, and the balance of aluminum, based on the total weight of the aluminum alloy.Type: GrantFiled: May 26, 2017Date of Patent: December 7, 2021Assignee: HAMILTON SUNDSTRAND CORPORATIONInventors: Eric Karlen, William Louis Wentland, Sergey Mironets, Robert Bianco
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Patent number: 11185923Abstract: A method for making an article is disclosed. The method involves inputting a digital model of an article into an additive manufacturing apparatus comprising an energy source. The additive manufacturing apparatus applies energy from the energy source to successively applied incremental quantities of a powder to fuse the powder to form the article corresponding to the digital model. The powder includes an aluminum alloy having 2.00-10.00 wt. % cerium, 0.50-2.50 wt. % titanium, 0-3.00 wt. % nickel, 0-0.75 wt. % nitrogen, 0-0.05 wt. % other alloying elements, and the balance of aluminum, based on the total weight of the aluminum alloy.Type: GrantFiled: May 26, 2017Date of Patent: November 30, 2021Assignee: HAMILTON SUNDSTRAND CORPORATIONInventors: Eric Karlen, William Louis Wentland, Sergey Mironets, Robert Bianco
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Publication number: 20210362267Abstract: A method for making an article is disclosed. According to the method, a digital model of the article is generated. The digital model is inputted into an additive manufacturing apparatus comprising an energy source. The additive manufacturing apparatus applies energy from the energy source to successively applied incremental quantities of a powder to fuse the powder to form the article corresponding to the digital model. The powder particles individually include a composite core including a first phase of a first metal and a second phase of a ceramic. A first shell including a second metal is disposed over the core.Type: ApplicationFiled: August 6, 2021Publication date: November 25, 2021Inventors: Eric Karlen, William Louis Wentland
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Patent number: 11130191Abstract: A method for making an article is disclosed. According to the method, a digital model of the article is generated. The digital model is inputted into an additive manufacturing apparatus comprising an energy source. The additive manufacturing apparatus applies energy from the energy source to successively applied incremental quantities of a powder to fuse the powder to form the article corresponding to the digital model. The powder particles individually include a composite core including a first phase of a first metal and a second phase of a ceramic. A first shell including a second metal is disposed over the core.Type: GrantFiled: July 22, 2016Date of Patent: September 28, 2021Assignee: HAMILTON SUNDSTRAND CORPORATIONInventors: Eric Karlen, William Louis Wentland
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Publication number: 20210054750Abstract: An airfoil assembly includes an airfoil body extending from a root to a tip defining a longitudinal axis therebetween. The airfoil body includes a leading edge between the root and the tip. A sheath is direct deposited on the airfoil body. The sheath includes at least one metallic material layer conforming to a surface of the airfoil body. In accordance with another aspect, a method for assembling an airfoil assembly includes directly depositing a plurality of material layers on an airfoil body to form a sheath. In accordance with some embodiments, the method includes partially curing the airfoil body.Type: ApplicationFiled: October 26, 2020Publication date: February 25, 2021Inventors: Eric Karlen, William L. Wentland, Daniel O. Ursenbach
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Patent number: 10815797Abstract: An airfoil assembly includes an airfoil body extending from a root to a tip defining a longitudinal axis therebetween. The airfoil body includes a leading edge between the root and the tip. A sheath is direct deposited on the airfoil body. The sheath includes at least one metallic material layer conforming to a surface of the airfoil body. In accordance with another aspect, a method for assembling an airfoil assembly includes directly depositing a plurality of material layers on an airfoil body to form a sheath. In accordance with some embodiments, the method includes partially curing the airfoil body.Type: GrantFiled: August 12, 2016Date of Patent: October 27, 2020Assignee: Hamilton Sundstrand CorporationInventors: Eric Karlen, William L. Wentland, Daniel O. Ursenbach
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Patent number: 10710212Abstract: A method of altering an additively manufactured part can include orienting a surface of the additively manufactured part toward a rotational center that may be independent of a rotational axis defined by the additively manufactured part, flowing an abrasive media past the surface, rotating the additively manufacturing part about the rotational center; urging abrasive particles in the abrasive media past the surface abrasive media to impinge the surface with centrifugal force generated by the rotating, and improving surface finish of the surface.Type: GrantFiled: October 30, 2017Date of Patent: July 14, 2020Assignee: Delavan Inc.Inventors: Eric Karlen, William Louis Wentland, Sergey Mironets
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Patent number: 10498116Abstract: An electrical power distribution system for a mobile platform, and a method for making such, includes a forming a substrate having a first panel connected to a second panel. The first panel resides in a first plane that differs from a second plan in which the second panel resides. One or more bus bars are arranged on the first panel, with one or more power electronic devices arranged on the first panel and connected to the one or more bus bars. One or more connectors are arranged on the second panel and electrically connected to the one or more bus bars. Finally, one or more thermal relief devices are arranged in contact with the substrate.Type: GrantFiled: November 15, 2017Date of Patent: December 3, 2019Assignee: HAMILTON SUNDSTRAND CORPORATIONInventors: Debabrata Pal, Michael Krenz, John Horowy, Eric Karlen
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Patent number: 10354768Abstract: A structure for preventing a scan by a beam is provided. The structure includes a primary material forming the structure. The primary material includes a first mass attenuation coefficient enabling the primary material to be penetrated by the beam. The structure also includes a matrix of dense particles within the primary material. The dense particles include secondary materials different than the primary material. The secondary materials comprise a subsequent mass attenuation coefficient that is greater than the first mass attenuation coefficient of the primary material. The subsequent mass attenuation coefficient enables the dense particles to attenuate the beam to distort the scan.Type: GrantFiled: January 10, 2017Date of Patent: July 16, 2019Assignee: HAMILTON SUNSTRAND CORPORATIONInventors: Eric Karlen, William Louis Wentland
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Publication number: 20190126435Abstract: A method of altering an additively manufactured part can include orienting a surface of the additively manufactured part toward a rotational center that may be independent of a rotational axis defined by the additively manufactured part, flowing an abrasive media past the surface, rotating the additively manufacturing part about the rotational center; urging abrasive particles in the abrasive media past the surface abrasive media to impinge the surface with centrifugal force generated by the rotating, and improving surface finish of the surface.Type: ApplicationFiled: October 30, 2017Publication date: May 2, 2019Inventors: Eric Karlen, William Louis Wentland, Sergey Mironets
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Patent number: 10259045Abstract: A method for forming a part includes: forming a first portion of the part at a first level; forming a second portion of the part at a second level; wherein forming the first and second portions includes exposing the first and second levels to a sintering process and portions of the first and second levels to an electron beam; causing a magnetorheological (MR) fluid to move into a passage inside the first and second portions; exposing the first and second portions to a magnetic field causing motion of particles in the MR fluid to move and break up sintered material in the passage; and removing some or all of the sintered material in the passage.Type: GrantFiled: September 21, 2015Date of Patent: April 16, 2019Assignee: HAMILTON SUNDSTRAND CORPORATIONInventors: Eric Karlen, Sergey Mironets, Diana Giulietti, Kiley James Versluys, Colette O. Fennessy, William Louis Wentland
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Patent number: 10220422Abstract: A method includes issuing a state change fluid into an internal passage of an additively manufactured article and causing the state change fluid to change from a first state having a first viscosity to a second state that is either solid or has a second viscosity that is higher than the first viscosity within the internal passage. The method can also include causing the state change fluid to change back from the second state to the first state and flushing the state change fluid from the internal passage to remove residual powder from the additively manufactured article.Type: GrantFiled: October 27, 2015Date of Patent: March 5, 2019Assignee: Hamilton Sundstrand CorporationInventors: Diana Giulietti, Eric Karlen, Sergey Mironets, Colette O. Fennessy, Kiley J. Versluys
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Patent number: 10225960Abstract: A magnetic device includes an electrically insulating body and a conductor coil. The insulating body defines an internal cavity for a magnetic device core and a coolant channel routed about the internal cavity. The conductor coil extends through the insulating body and winds about the internal cavity. The electrically insulating body electrically insulates the internal cavity and coolant channel from the conductor coil.Type: GrantFiled: February 19, 2016Date of Patent: March 5, 2019Assignee: Hamilton Sundstrand CorporationInventors: Charles Shepard, Eric Karlen
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Patent number: 10195667Abstract: A method includes placing an additively manufactured article having one or more internal channels in a non-reactive liquid to remove remainder powder from within the one or more internal channels, wherein the non-reactive liquid is a gas at room temperature and/or pressure. Placing the additively manufactured article in the non-reactive liquid includes can include placing the additively manufactured article in liquid nitrogen.Type: GrantFiled: November 23, 2015Date of Patent: February 5, 2019Assignee: Delavan Inc.Inventors: Diana Giulietti, Eric Karlen, Kiley J. Versluys