Patents by Inventor Gagandeep Saini
Gagandeep Saini 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: 11911977Abstract: An illustrative example of the present disclosure provides a machine configured to form a composite structure. The machine includes a composite placement machine, measuring equipment, a tool path generator, and compaction equipment. The composite placement machine lays up composite plies. The measuring equipment measures surfaces of the composite plies to form measurements during layup of the composite plies. A computer includes a model of the composite plies for a structure. The tool path generator forms a modified tool path based upon a difference between the measurements and expected measurements for the composite plies in the model.Type: GrantFiled: May 6, 2021Date of Patent: February 27, 2024Assignee: The Boeing CompanyInventors: Michael Kenneth-Que Louie, Robert Graham Albers, Jeron D. Moore, Luis A. Perla, Gagandeep Saini, Brice A. Johnson, Marcin A. Rabiega
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Patent number: 11806954Abstract: A composite charge is formed between two compression dies into a composite laminate stiffener. The stiffener is contoured along its length by contouring the dies. Wrinkle diffusers attached to, or embedded or incorporated into the tool surfaces of the dies, diffuse wrinkles formed on the inside radius of the stiffener during the contouring.Type: GrantFiled: December 14, 2021Date of Patent: November 7, 2023Assignee: The Boeing CompanyInventors: Gagandeep Saini, Ian Edward Schroeder, Kurtis Shuldberg Willden, Lisa Christina Carlson
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Publication number: 20230278297Abstract: Composite laminate stiffeners such as stringers are punch formed between first and second universal dies respectively carried on first and second trays. The second tray is mounted for sliding movement relative to the first tray between a punch position and a compaction position. Parts of the first and second dies are easily reconfigurable, allowing different shapes of stiffeners to be formed on the same forming apparatus.Type: ApplicationFiled: March 7, 2022Publication date: September 7, 2023Inventors: Lisa Christina Carlson, Silas Lawton Studley, Daniel Saeil Martin, Kurtis Shuldberg Willden, Gagandeep Saini, Steven Joseph Plummer
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Publication number: 20230182417Abstract: A composite charge is formed between two compression dies into a composite laminate stiffener. The stiffener is contoured along its length by contouring the dies. Wrinkle diffusers attached to, or embedded or incorporated into the tool surfaces of the dies, diffuse wrinkles formed on the inside radius of the stiffener during the contouring.Type: ApplicationFiled: December 14, 2021Publication date: June 15, 2023Inventors: Gagandeep Saini, Ian Edward Schroeder, Kurtis Shuldberg Willden, Lisa Christina Carlson
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Patent number: 11518121Abstract: A composite laminate stiffener is formed to contour with reduced ply wrinkling using constrained creep forming. The tooling apparatus is provided with flexible cauls which constrain the stiffener during the contour forming process. The creep forming is carried out at a slow enough rate so that friction or shear resistance between the resin and fibers of the plies remains low enough that slippage can occur and significant compression stresses are not generated rate, allowing relaxation of residual stresses in the stiffener.Type: GrantFiled: October 14, 2019Date of Patent: December 6, 2022Assignee: The Boeing CompanyInventors: Gagandeep Saini, Lisa Christina Carlson, Kurtis Shuldberg Willden, Brian James Smith, Jonathan Santiago
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Publication number: 20220355556Abstract: A method for positioning wrinkling of a cured composite material at a predetermined location in fabricating a composite part, which includes positioning a caul plate in contact with an uncured composite material. The uncured composite material has a geometric change in shape and the caul plate has a first slit which extends through and along the caul plate. The method further includes positioning a fiber and a resin of a portion of the uncured composite material within the first slit and curing the uncured composite material positioning a wrinkle within the first slit of the caul plate.Type: ApplicationFiled: July 25, 2022Publication date: November 10, 2022Inventor: Gagandeep Saini
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Patent number: 11426957Abstract: A flexible caul for applying pressure to a part comprises a caul member having a plurality of spaced apart gaps therein to provide the caul member with flexibility, and a flexible covering that limits flexing of the caul member.Type: GrantFiled: October 14, 2019Date of Patent: August 30, 2022Assignee: The Boeing CompanyInventors: Gagandeep Saini, Lisa Christina Carlson, Jonathan Santiago, Kurtis Shuldberg Willden
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Patent number: 11307029Abstract: A method for analyzing a surface quality of a laminate part including the steps of creating a planned dimensioned representation of a laminate part desired to be built which includes a first surface having a first topography; placing fibers into locations for the laminate part desired to be built; and curing a resin associated with the placed fibers fabricating an as-built laminate part which includes a second surface having a second topography which corresponds to the first surface having the first topography. The method also includes aligning the first surface, the second surface and the locations of the fibers; determining a first elevation of a first point on the first surface and a second elevation of a second point on the second surface; and observing the first surface, the second surface and the locations of the fibers in alignment and the first elevation relative to the second elevation in analyzing the surface quality of the laminate part.Type: GrantFiled: April 2, 2018Date of Patent: April 19, 2022Assignee: THE BOEING COMPANYInventors: Jeron D. Moore, Michael K. Louie, Luis A. Perla, Gagandeep Saini, Christopher W. Fay, Robert G. Meyer
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Publication number: 20210252807Abstract: An illustrative example of the present disclosure provides a method. A first set of composite plies including a first outer ply of a first composite structure is laid up. A first intermediate surface of the first outer ply is measured to form a first set of measurements. A laydown surface for a tool path of a composite placement machine is modified to form a modified tool path, wherein modifying the laydown surface comprises modifying the laydown surface such that a laydown surface of the modified tool path matches the first set of measurements. A composite ply is laid down using the composite placement machine and the modified tool path.Type: ApplicationFiled: May 6, 2021Publication date: August 19, 2021Inventors: Michael Kenneth-Que Louie, Robert Graham Albers, Jeron D. Moore, Luis A. Perla, Gagandeep Saini, Brice A. Johnson, Marcin A. Rabiega
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Patent number: 11090882Abstract: In one version there is provided a test system including a layup tool having a layup surface, and two fairing bars attached to the layup surface. The test system includes the composite laminate having a plurality of stacked plies, and positioned between the two fairing bars. The test system includes fiber distortion initiator(s) positioned at one or more locations under, and adjacent to, one or more plies of the plurality of stacked plies. The test system includes two caul plates with a gap in between, and positioned over the composite laminate. When the test system undergoes a pressurized cure process with a vacuum compaction, a restricted outward expansion of the plurality of stacked plies by the fairing bars, and a pressure differential region formed by the one or more fiber distortion initiators at the one or more locations, create the controlled and repeatable out-of-plane fiber distortion in the composite laminate.Type: GrantFiled: September 26, 2018Date of Patent: August 17, 2021Assignee: The Boeing CompanyInventors: Gagandeep Saini, Karl M. Nelson, William H. Ingram
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Patent number: 11034100Abstract: A method and apparatus for forming a composite object. A first plurality of tows is laid up over a tool according to a first path. A second plurality of tows is laid up over the tool according to a second path. A first portion of the first plurality of tows runs non-parallel to a second portion of the second plurality of tows. First ends of the first portion of the first plurality of tows and second ends of the second portion of the second plurality of tows meet at a merge zone along the tool to form a ply of a composite laminate.Type: GrantFiled: June 20, 2018Date of Patent: June 15, 2021Assignee: The Boeing CompanyInventors: Michael Kenneth-Que Louie, Jeron D. Moore, Gagandeep Saini, Luis A. Perla, Brice Aaron Johnson, Stewart James Ibbotson, Timothy D. Jackson, Robert G. Meyer, Robert Graham Albers
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Patent number: 11020913Abstract: A process and system for improving surface quality of composite structures, including laying up a first set of composite plies including a first outer ply of a first composite structure. A first intermediate surface of the first outer ply is measured to form a first set of measurements. A laydown surface for a tool path of a composite placement machine is modified to form a modified tool path, wherein modifying the laydown surface comprises modifying the laydown surface such that a laydown surface of the modified tool path matches the first set of measurements. A composite ply is laid down using the composite placement machine and the modified tool path.Type: GrantFiled: May 11, 2018Date of Patent: June 1, 2021Assignee: The Boeing CompanyInventors: Michael Kenneth-Que Louie, Robert Graham Albers, Jeron D. Moore, Luis A. Perla, Gagandeep Saini, Brice A. Johnson, Marcin A. Rabiega
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Publication number: 20210107238Abstract: A composite laminate stiffener is formed to contour with reduced ply wrinkling using constrained creep forming. The tooling apparatus is provided with flexible cauls which constrain the stiffener during the contour forming process. The creep forming is carried out at a slow enough rate so that friction or shear resistance between the resin and fibers of the plies remains low enough that slippage can occur and significant compression stresses are not generated rate, allowing relaxation of residual stresses in the stiffener.Type: ApplicationFiled: October 14, 2019Publication date: April 15, 2021Inventors: Gagandeep Saini, Lisa Christina Carlson, Kurtis Shuldberg Willden, Brian James Smith, Jonathan Santiago
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Publication number: 20210107239Abstract: A flexible caul for applying pressure to a part comprises a caul member having a plurality of spaced apart gaps therein to provide the caul member with flexibility, and a flexible covering that limits flexing of the caul member.Type: ApplicationFiled: October 14, 2019Publication date: April 15, 2021Inventors: Gagandeep Saini, Lisa Christina Carlson, Jonathan Santiago, Kurtis Shuldberg Willden
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Patent number: 10974465Abstract: A method and system for forming a composite laminate. A layup plan is generated for laying up a plurality of plies having a plurality of merge zones, each ply of the plurality of plies having a corresponding merge zone at which ends of a first plurality of tows for each ply and ends of a second plurality of tows for each ply meet. The locations of the plurality of merge zones are offset relative to each other through a thickness of the composite laminate. The plurality of plies is then laid up according to the layup plan to form a composite laminate.Type: GrantFiled: June 20, 2018Date of Patent: April 13, 2021Assignee: The Boeing CompanyInventors: Jeron D. Moore, Michael Kenneth-Que Louie, Gagandeep Saini, Luis A. Perla, Brice Aaron Johnson, Stewart James Ibbotson, Robert G. Meyer
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Patent number: 10814533Abstract: A vacuum probe comprises a sharpened body that is displaceable downward and toward a vacuum bag during vacuum hose quick connection. The sharpened body and a valve element inside the vacuum probe move in tandem until the sharpened body projects outside the vacuum probe. A vacuum pressure applied via the vacuum hose pulls the vacuum bag upwards and towards the projecting sharpened body, which then punctures the vacuum bag, thereby enabling air under the vacuum bag to be evacuated via the vacuum probe as vacuum pressure continues to be applied.Type: GrantFiled: November 30, 2017Date of Patent: October 27, 2020Assignee: The Boeing CompanyInventors: Michael K. Louie, Kenneth M. Dull, Gagandeep Saini
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Publication number: 20200254702Abstract: A caul plate for application onto an uncured composite material which includes a first slit defined by and which extends through and along the caul plate. Further included is a method for curing a composite material part having geometric change within the part. The method includes fabricating a part constructed from uncured composite material having a geometric change within the uncured composite material, which includes a step of positioning a caul plate in overlying relationship to the uncured composite material having a geometric change in the uncured composite material, wherein the caul plate includes a first slit defined by and which extends through and along the caul plate.Type: ApplicationFiled: February 7, 2019Publication date: August 13, 2020Inventor: Gagandeep Saini
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Publication number: 20200094497Abstract: In one version there is provided a test system including a layup tool having a layup surface, and two fairing bars attached to the layup surface. The test system includes the composite laminate having a plurality of stacked plies, and positioned between the two fairing bars. The test system includes fiber distortion initiator(s) positioned at one or more locations under, and adjacent to, one or more plies of the plurality of stacked plies. The test system includes two caul plates with a gap in between, and positioned over the composite laminate. When the test system undergoes a pressurized cure process with a vacuum compaction, a restricted outward expansion of the plurality of stacked plies by the fairing bars, and a pressure differential region formed by the one or more fiber distortion initiators at the one or more locations, create the controlled and repeatable out-of-plane fiber distortion in the composite laminate.Type: ApplicationFiled: September 26, 2018Publication date: March 26, 2020Inventors: Gagandeep Saini, Karl M. Nelson, William H. Ingram
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Publication number: 20190389149Abstract: A method and system for forming a composite laminate. A layup plan is generated for laying up a plurality of plies having a plurality of merge zones, each ply of the plurality of plies having a corresponding merge zone at which ends of a first plurality of tows for each ply and ends of a second plurality of tows for each ply meet. The locations of the plurality of merge zones are offset relative to each other through a thickness of the composite laminate. The plurality of plies is then laid up according to the layup plan to form a composite laminate.Type: ApplicationFiled: June 20, 2018Publication date: December 26, 2019Inventors: Jeron D. Moore, Michael Kenneth-Que Louie, Gagandeep Saini, Luis A. Perla, Brice Aaron Johnson, Stewart James Ibbotson, Robert G. Meyer
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Publication number: 20190389150Abstract: A method and apparatus for forming a composite object. A first plurality of tows is laid up over a tool according to a first path. A second plurality of tows is laid up over the tool according to a second path. A first portion of the first plurality of tows runs non-parallel to a second portion of the second plurality of tows. First ends of the first portion of the first plurality of tows and second ends of the second portion of the second plurality of tows meet at a merge zone along the tool to form a ply of a composite laminate.Type: ApplicationFiled: June 20, 2018Publication date: December 26, 2019Inventors: Michael Kenneth-Que Louie, Jeron D. Moore, Gagandeep Saini, Luis A. Perla, Brice Aaron Johnson, Stewart James Ibbotson, Timothy D. Jackson, Robert G. Meyer, Robert Graham Albers