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).

  • Patent number: 11130191
    Abstract: 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: Grant
    Filed: July 22, 2016
    Date of Patent: September 28, 2021
    Assignee: HAMILTON SUNDSTRAND CORPORATION
    Inventors: Eric Karlen, William Louis Wentland
  • Publication number: 20210054750
    Abstract: 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: Application
    Filed: October 26, 2020
    Publication date: February 25, 2021
    Inventors: Eric Karlen, William L. Wentland, Daniel O. Ursenbach
  • Patent number: 10815797
    Abstract: 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: Grant
    Filed: August 12, 2016
    Date of Patent: October 27, 2020
    Assignee: Hamilton Sundstrand Corporation
    Inventors: Eric Karlen, William L. Wentland, Daniel O. Ursenbach
  • Patent number: 10710212
    Abstract: 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: Grant
    Filed: October 30, 2017
    Date of Patent: July 14, 2020
    Assignee: Delavan Inc.
    Inventors: Eric Karlen, William Louis Wentland, Sergey Mironets
  • Patent number: 10498116
    Abstract: 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: Grant
    Filed: November 15, 2017
    Date of Patent: December 3, 2019
    Assignee: HAMILTON SUNDSTRAND CORPORATION
    Inventors: Debabrata Pal, Michael Krenz, John Horowy, Eric Karlen
  • Patent number: 10354768
    Abstract: 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: Grant
    Filed: January 10, 2017
    Date of Patent: July 16, 2019
    Assignee: HAMILTON SUNSTRAND CORPORATION
    Inventors: Eric Karlen, William Louis Wentland
  • Publication number: 20190126435
    Abstract: 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: Application
    Filed: October 30, 2017
    Publication date: May 2, 2019
    Inventors: Eric Karlen, William Louis Wentland, Sergey Mironets
  • Patent number: 10259045
    Abstract: 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: Grant
    Filed: September 21, 2015
    Date of Patent: April 16, 2019
    Assignee: HAMILTON SUNDSTRAND CORPORATION
    Inventors: Eric Karlen, Sergey Mironets, Diana Giulietti, Kiley James Versluys, Colette O. Fennessy, William Louis Wentland
  • Patent number: 10225960
    Abstract: 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: Grant
    Filed: February 19, 2016
    Date of Patent: March 5, 2019
    Assignee: Hamilton Sundstrand Corporation
    Inventors: Charles Shepard, Eric Karlen
  • Patent number: 10220422
    Abstract: 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: Grant
    Filed: October 27, 2015
    Date of Patent: March 5, 2019
    Assignee: Hamilton Sundstrand Corporation
    Inventors: Diana Giulietti, Eric Karlen, Sergey Mironets, Colette O. Fennessy, Kiley J. Versluys
  • Patent number: 10195667
    Abstract: 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: Grant
    Filed: November 23, 2015
    Date of Patent: February 5, 2019
    Assignee: Delavan Inc.
    Inventors: Diana Giulietti, Eric Karlen, Kiley J. Versluys
  • Publication number: 20180339339
    Abstract: 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: Application
    Filed: May 26, 2017
    Publication date: November 29, 2018
    Inventors: Eric Karlen, William Louis Wentland, Sergey Mironets, Robert Bianco
  • Publication number: 20180339340
    Abstract: 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: Application
    Filed: May 26, 2017
    Publication date: November 29, 2018
    Inventors: Eric Karlen, William Louis Wentland, Sergey Mironets, Robert Bianco
  • Patent number: 10109542
    Abstract: A solid-state contactor includes a housing, a lead, a bus plate, and an end connector. The lead extends through the housing and into an interior of the housing. The bus plate is disposed within the housing interior and mounts a die which is electrically connected to the lead through the bus plate. The end connector extends between the bus plate and the lead, attaching to the bus plate at an angle for coupling a plurality of bus plates with die to the lead in a stacked arrangement.
    Type: Grant
    Filed: April 4, 2014
    Date of Patent: October 23, 2018
    Assignees: Hamilton Sundstrand Corporation, HS Elektronik Systeme GmbH
    Inventors: Pal Debabrata, John Horowy, Eric Karlen, Rainer J. Seidel
  • Patent number: 10048019
    Abstract: A heat exchanger includes a body defining a flow channel, and a pin extending across the flow channel, the pin including an at least partially non-cylindrical shape. The pin can be a double helix pin including two spiral branches defining a double helix shape. The two branches can include a uniform winding radius. The two branches include a non-uniform winding radius. The non-uniform winding radius can include a base radius and a midpoint radius, wherein the midpoint radius is smaller than the base radius. The two branches can be joined together by one or more cross-members.
    Type: Grant
    Filed: December 22, 2014
    Date of Patent: August 14, 2018
    Assignee: Hamilton Sundstrand Corporation
    Inventors: Eric Karlen, William L. Wentland
  • Patent number: 10049819
    Abstract: Embodiments are directed to obtaining a specification of at least one operational requirement for at least one capacitor, generating a design of the at least one capacitor to satisfy the at least one operational requirement, the design of the at least one capacitor comprising a plurality of layers and a first integrated busbar coupled to at least a portion of the layers, and based on the design, manufacturing the at least one capacitor by utilizing an additive manufacturing technique.
    Type: Grant
    Filed: December 14, 2016
    Date of Patent: August 14, 2018
    Assignee: HAMILTON SUNDSTRAND CORPORATION
    Inventors: John Horowy, Gary L. Galloway, Debabrata Pal, Eric Karlen, Mark W. Metzler
  • Patent number: 10030288
    Abstract: A method for making an article is disclosed. The method involves first generating a digital model of the article. 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 includes an aluminum alloy having 90.15-95.80 wt. % aluminum, 3.00-4.50 wt. % silicon, 0.70-1.50 wt. % magnesium, 0.50-1.00 wt. % manganese, 0-0.50 wt. % iron, 0-0.10 wt. % copper, 0-0.50 wt. % titanium, 0-0.20 wt. % boron, 0-1.50 wt. % nickel, and 0-0.05 wt. % other alloying elements, based on the total weight of the aluminum alloy.
    Type: Grant
    Filed: July 16, 2015
    Date of Patent: July 24, 2018
    Assignee: HAMILTON SUNDSTRAND CORPORATION
    Inventors: Eric Karlen, William Louis Wentland, Sergey Mironets, Thomas J. Ocken, Robert Bianco
  • Publication number: 20180200829
    Abstract: A friction stir welded component includes a channel body having a main surface and an elongated channel formed in the main surface. The elongated channel has a first depth portion that is longitudinally spanned by shoulders having a second depth, the second depth being shallower than the first depth. The body further has an abutting face that connects the main surface with one of the shoulders at an oblique angle relative to the main surface. A channel cover with an abutting face is seated against the abutting face of the channel body. A friction stir weld joint joins the channel cover to the channel body, wherein the friction stir weld joint is defined along abutting faces of the channel body and channel cover.
    Type: Application
    Filed: January 19, 2017
    Publication date: July 19, 2018
    Inventors: Kris H. Campbell, Mark W. Metzler, Eric A. Carter, Anthony L. Biermann, John Horowy, Eric Karlen, Debabrata Pal
  • Publication number: 20180197645
    Abstract: 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: Application
    Filed: January 10, 2017
    Publication date: July 12, 2018
    Inventors: Eric Karlen, William Louis Wentland
  • Publication number: 20180083425
    Abstract: 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: Application
    Filed: November 15, 2017
    Publication date: March 22, 2018
    Inventors: Debabrata Pal, Michael Krenz, John Horowy, Eric Karlen