Patents by Inventor Jeffery L. Marcoe

Jeffery L. Marcoe 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).

  • Publication number: 20180290402
    Abstract: A fiber placement system including a fiber placement station at a first location, the fiber placement station including a tool and a fiber placement assembly configured to construct a reinforcement layup on the tool, the first fiber placement assembly including a compaction roller rotatable about an axis of rotation, the compaction roller at least partially defining a nip, a thermoplastic composite ply extending through the nip and a heating unit positioned to heat the thermoplastic composite ply proximate the nip, and a consolidation station at a consolidation location, the consolidation location being different from the first location, the consolidation station including a consolidation tool and a consolidation system configured to consolidate a reinforcement layup assembly that includes the reinforcement layup.
    Type: Application
    Filed: June 14, 2018
    Publication date: October 11, 2018
    Applicant: The Boeing Company
    Inventors: Marc R. Matsen, Mark A. Negley, Jeffery L. Marcoe, Stephen G. Moore, Brice A. Johnson, Alexandra K. Dillon, Megan M. Petersen
  • Publication number: 20180243972
    Abstract: Systems and processes that integrate thermoplastic and shape memory alloy materials to form an adaptive composite structure capable of changing its shape. For example, the adaptive composite structure may be designed to serve as a multifunctional adaptive wing flight control surface. Other applications for such adaptive composite structures include in variable area fan nozzles, winglets, fairings, elevators, rudders, or other aircraft components having an aerodynamic surface whose shape is preferably controllable. The material systems can be integrated by means of overbraiding (interwoven) with tows of both thermoplastic and shape memory alloy materials or separate layers of each material can be consolidated (e.g., using induction heating) to make a flight control surface that does not require separate actuation.
    Type: Application
    Filed: April 26, 2018
    Publication date: August 30, 2018
    Applicant: The Boeing Company
    Inventors: Jeffery L. Marcoe, Sahrudine Apdalhaliem, Moushumi Shome
  • Patent number: 10058950
    Abstract: An induction welding system is provided. The system includes at least one induction coil configured to generate an alternating magnetic field, and a smart susceptor film sized to be positioned between a first component and a second component to be welded to the first component. The smart susceptor film includes a thermoplastic resin, and a plurality of metal alloy wires disposed in the thermoplastic resin such that the plurality of metal alloy wires are oriented substantially parallel to the generated alternating magnetic field.
    Type: Grant
    Filed: October 25, 2012
    Date of Patent: August 28, 2018
    Assignee: The Boeing Company
    Inventors: Noel T. Gerken, Robert James Miller, Jeffery L. Marcoe, John B. Moser, Aaron W. Bartel, Marc R. Matsen
  • Patent number: 10016947
    Abstract: A fiber placement system including a fiber placement station at a first location, the fiber placement station including a tool and a fiber placement assembly configured to construct a reinforcement layup on the tool, the first fiber placement assembly including a compaction roller rotatable about an axis of rotation, the compaction roller at least partially defining a nip, a thermoplastic composite ply extending through the nip and a heating unit positioned to heat the thermoplastic composite ply proximate the nip, and a consolidation station at a consolidation location, the consolidation location being different from the first location, the consolidation station including a consolidation tool and a consolidation system configured to consolidate a reinforcement layup assembly that includes the reinforcement layup.
    Type: Grant
    Filed: May 21, 2015
    Date of Patent: July 10, 2018
    Assignee: The Boeing Company
    Inventors: Marc R. Matsen, Mark A. Negley, Jeffery L. Marcoe, Stephen G. Moore, Brice A. Johnson, Alexandra K. Dillon, Megan M. Petersen
  • Patent number: 9981444
    Abstract: A composite stiffener is fabricated using preforms of laminated, unidirectional composite tape. The stiffener includes a void that is reinforced by a filler wrapped with a structural adhesive. The surfaces of the preforms surrounding the void include a layer of composite fabric which is bonded to the filler by the adhesive, thereby increasing the toughness of stiffeners around the void and improving pull-off strength of the stiffener.
    Type: Grant
    Filed: June 27, 2013
    Date of Patent: May 29, 2018
    Assignee: THE BOEING COMPANY
    Inventors: Lyle R. Deobald, John D. Morris, Karl B. Lee, Jeffery L. Marcoe, Mark C. Iden, Christopher G. Harris
  • Patent number: 9981421
    Abstract: Systems and processes that integrate thermoplastic and shape memory alloy materials to form an adaptive composite structure capable of changing its shape. For example, the adaptive composite structure may be designed to serve as a multifunctional adaptive wing flight control surface. Other applications for such adaptive composite structures include in variable area fan nozzles, winglets, fairings, elevators, rudders, or other aircraft components having an aerodynamic surface whose shape is preferably controllable. The material systems can be integrated by means of overbraiding (interwoven) with tows of both thermoplastic and shape memory alloy materials or separate layers of each material can be consolidated (e.g., using induction heating) to make a flight control surface that does not require separate actuation.
    Type: Grant
    Filed: July 16, 2014
    Date of Patent: May 29, 2018
    Assignee: The Boeing Company
    Inventors: Jeffery L. Marcoe, Sahrudine Apdalhaliem, Moushumi Shome
  • Publication number: 20180065314
    Abstract: A radius filler includes a plurality of fibers encapsulated in resin and braided into a braided radius filler. The braided radius filler has a substantially triangular shape with concave radius filler side surfaces and a substantially planar radius filler base surface.
    Type: Application
    Filed: October 30, 2017
    Publication date: March 8, 2018
    Inventors: Angelo Rossi, Jeffery L. Marcoe, Marc R. Matsen, Aaron W. Bartel, Waeil M. Ashmawi, Sahrudine Apdalhaliem, Adriana Willempje Blom-Schieber, David Reusch
  • Patent number: 9827710
    Abstract: A method of manufacturing a radius filler may include providing a plurality of fibers, braiding the plurality of fibers into a braided preform, shaping the braided preform into a braided radius filler, and cutting the braided radius filler to a desired length.
    Type: Grant
    Filed: February 4, 2014
    Date of Patent: November 28, 2017
    Assignee: The Boeing Company
    Inventors: Angelo Rossi, Jeffery L. Marcoe, Marc R. Matsen, Aaron W. Bartel
  • Patent number: 9808996
    Abstract: In an embodiment of the disclosure, there is provided a method of fabricating a thermoplastic torque box assembly. The method includes providing a plurality of braided thermoplastic tubular spar caps, connecting one or more connector elements to one or more of the braided thermoplastic tubular spar caps, and laying up an inner thermoplastic facesheet in a continuous manner around the one or more braided thermoplastic tubular spar caps. The method further includes attaching a plurality of skin panel stabilization elements to the inner thermoplastic facesheet to define four torque box side portions, laying up and attaching an outer thermoplastic facesheet in a continuous manner around the plurality of skin panel stabilization elements, and heating at an effective temperature and an effective pressure the thermoplastic torque box assembly.
    Type: Grant
    Filed: August 26, 2014
    Date of Patent: November 7, 2017
    Assignee: The Boeing Company
    Inventor: Jeffery L. Marcoe
  • Publication number: 20170292547
    Abstract: Provided are assemblies having composite structures interlocked with shape memory alloy structures and methods of fabricating such assemblies. Interlocking may involve inserting an interlocking protrusion of a shape memory alloy structure into an interlocking opening of a composite structure and heating at least this protrusion of the shape memory alloy structure to activate the alloy and change the shape of the protrusion. This shape change engages the protrusion in the opening such that the protrusion cannot be removed from the opening. The shape memory alloy structure may be specifically trained prior to forming an assembly using a combination of thermal cycling and deformation to achieve specific pre-activation and post-activation shapes. The pre-activation shape allows inserting the interlocking protrusion into the opening, while the post-activation shape engages the interlocking protrusion within the opening. As such, activation of the shape memory alloy interlocks the two structures.
    Type: Application
    Filed: June 22, 2017
    Publication date: October 12, 2017
    Applicant: The Boeing Company
    Inventors: Waeil M. Ashmawi, Jaime C. Garcia, Sahrudine Apdalhaliem, Jeffery L. Marcoe, Moushumi Shome
  • Patent number: 9719536
    Abstract: Provided are assemblies having composite structures interlocked with shape memory alloy structures and methods of fabricating such assemblies. Interlocking may involve inserting an interlocking protrusion of a shape memory alloy structure into an interlocking opening of a composite structure and heating at least this protrusion of the shape memory alloy structure to activate the alloy and change the shape of the protrusion. This shape change engages the protrusion in the opening such that the protrusion cannot be removed from the opening. The shape memory alloy structure may be specifically trained prior to forming an assembly using a combination of thermal cycling and deformation to achieve specific pre-activation and post-activation shapes. The pre-activation shape allows inserting the interlocking protrusion into the opening, while the post-activation shape engages the interlocking protrusion within the opening. As such, activation of the shape memory alloy interlocks the two structures.
    Type: Grant
    Filed: July 3, 2014
    Date of Patent: August 1, 2017
    Assignee: The Boeing Company
    Inventors: Waeil M. Ashmawi, Jaime C. Garcia, Sahrudine Apdalhaliem, Jeffery L. Marcoe, Moushumi Shome
  • Publication number: 20160339647
    Abstract: A fiber placement system including a fiber placement station at a first location, the fiber placement station including a tool and a fiber placement assembly configured to construct a reinforcement layup on the tool, the first fiber placement assembly including a compaction roller rotatable about an axis of rotation, the compaction roller at least partially defining a nip, a thermoplastic composite ply extending through the nip and a heating unit positioned to heat the thermoplastic composite ply proximate the nip, and a consolidation station at a consolidation location, the consolidation location being different from the first location, the consolidation station including a consolidation tool and a consolidation system configured to consolidate a reinforcement layup assembly that includes the reinforcement layup.
    Type: Application
    Filed: May 21, 2015
    Publication date: November 24, 2016
    Inventors: Marc R. Matsen, Mark A. Negley, Jeffery L. Marcoe, Stephen G. Moore, Brice A. Johnson, Alexandra K. Dillon, Megan M. Petersen
  • Publication number: 20160016355
    Abstract: Systems and processes that integrate thermoplastic and shape memory alloy materials to form an adaptive composite structure capable of changing its shape. For example, the adaptive composite structure may be designed to serve as a multifunctional adaptive wing flight control surface. Other applications for such adaptive composite structures include in variable area fan nozzles, winglets, fairings, elevators, rudders, or other aircraft components having an aerodynamic surface whose shape is preferably controllable. The material systems can be integrated by means of overbraiding (interwoven) with tows of both thermoplastic and shape memory alloy materials or separate layers of each material can be consolidated (e.g., using induction heating) to make a flight control surface that does not require separate actuation.
    Type: Application
    Filed: July 16, 2014
    Publication date: January 21, 2016
    Applicant: THE BOEING COMPANY
    Inventors: Jeffery L. Marcoe, Sahrudine Apdalhaliem, Moushumi Shome
  • Publication number: 20160003280
    Abstract: Provided are assemblies having composite structures interlocked with shape memory alloy structures and methods of fabricating such assemblies. Interlocking may involve inserting an interlocking protrusion of a shape memory alloy structure into an interlocking opening of a composite structure and heating at least this protrusion of the shape memory alloy structure to activate the alloy and change the shape of the protrusion. This shape change engages the protrusion in the opening such that the protrusion cannot be removed from the opening. The shape memory alloy structure may be specifically trained prior to forming an assembly using a combination of thermal cycling and deformation to achieve specific pre-activation and post-activation shapes. The pre-activation shape allows inserting the interlocking protrusion into the opening, while the post-activation shape engages the interlocking protrusion within the opening. As such, activation of the shape memory alloy interlocks the two structures.
    Type: Application
    Filed: July 3, 2014
    Publication date: January 7, 2016
    Applicant: The Boeing Company
    Inventors: Waeil M. Ashmawi, Jaime C. Garcia, Sahrudine Apdalhaliem, Jeffery L. Marcoe, Moushumi Shome
  • Patent number: 9174393
    Abstract: A method of fabricating a thermoplastic composite tubular structure provides a mandrel of a soluble, expandable material. The method overbraids the mandrel with a continuous fiber thermoplastic composite material to form an overbraided mandrel. The method installs the overbraided mandrel into a matched tooling assembly. The method heats in a heating apparatus the matched tooling assembly with the installed overbraided mandrel at a specified heating profile in order to consolidate the thermoplastic composite material and form a thermoplastic composite tubular structure. The method cools the matched tooling assembly with the formed thermoplastic composite tubular structure at a specified cooling profile. The method removes the formed thermoplastic composite tubular structure from the matched tooling assembly. The method solubilizes the mandrel to permanently remove the mandrel from the formed thermoplastic composite tubular structure.
    Type: Grant
    Filed: October 12, 2012
    Date of Patent: November 3, 2015
    Assignee: The Boeing Company
    Inventors: Aaron W. Bartel, Brett I. Lyons, Jeffery L. Marcoe
  • Publication number: 20150217508
    Abstract: A method of manufacturing a radius filler may include providing a plurality of fibers, braiding the plurality of fibers into a braided preform, shaping the braided preform into a braided radius filler, and cutting the braided radius filler to a desired length.
    Type: Application
    Filed: February 4, 2014
    Publication date: August 6, 2015
    Applicant: The Boeing Company
    Inventors: Angelo Rossi, Waeil M. Ashmawi, Sahrudine Apdalhaliem, Jeffery L. Marcoe, Marc R. Matsen, Aaron W. Bartel, Adriana Willempje Blom, David Reusch
  • Patent number: 8973871
    Abstract: There is provided a box structure for carrying load having upper and lower composite integrated sandwich panels. The panels have facesheets sandwiching one or more core portions and adjacent dense packs oriented in an axial direction. The box structure further has a plurality of spars. Each spar has a web and web attachments and has a spar length in the axial direction. The plurality of spars are connected to the panels with the web attachments located at the dense packs. The facesheets are configured to carry primarily torsion and pressure loads in shear and no significant axial loads. The dense packs are configured to carry all significant box bending in axial tension and compression loads.
    Type: Grant
    Filed: January 26, 2013
    Date of Patent: March 10, 2015
    Assignee: The Boeing Company
    Inventors: Jeffery L. Marcoe, Paul S. Nordman, Stephen T. Brown, William G. Roeseler, Terry K. Isomura, Willard N. Westre
  • Publication number: 20140360654
    Abstract: In an embodiment of the disclosure, there is provided a method of fabricating a thermoplastic torque box assembly. The method includes providing a plurality of braided thermoplastic tubular spar caps, connecting one or more connector elements to one or more of the braided thermoplastic tubular spar caps, and laying up an inner thermoplastic facesheet in a continuous manner around the one or more braided thermoplastic tubular spar caps. The method further includes attaching a plurality of skin panel stabilization elements to the inner thermoplastic facesheet to define four torque box side portions, laying up and attaching an outer thermoplastic facesheet in a continuous manner around the plurality of skin panel stabilization elements, and heating at an effective temperature and an effective pressure the thermoplastic torque box assembly.
    Type: Application
    Filed: August 26, 2014
    Publication date: December 11, 2014
    Inventor: Jeffery L. Marcoe
  • Patent number: 8540833
    Abstract: A composite stiffener is fabricated using preforms of laminated, unidirectional composite tape. The stiffener includes a void that is reinforced by a filler wrapped with a structural adhesive. The surfaces of the preforms surrounding the void include a layer of composite fabric which is bonded to the filler by the adhesive, thereby increasing the toughness of stiffeners around the void and improving pull-off strength of the stiffener.
    Type: Grant
    Filed: May 16, 2008
    Date of Patent: September 24, 2013
    Assignee: The Boeing Company
    Inventors: Lyle R. Deobald, John D. Morris, Karl B. Lee, Jeffery L. Marcoe, Mark C. Iden, Christopher G. Harris
  • Publication number: 20090317587
    Abstract: A composite stiffener is fabricated using preforms of laminated, unidirectional composite tape. The stiffener includes a void that is reinforced by a filler wrapped with a structural adhesive. The surfaces of the preforms surrounding the void include a layer of composite fabric which is bonded to the filler by the adhesive, thereby increasing the toughness of stiffeners around the void and improving pull-off strength of the stiffener.
    Type: Application
    Filed: May 16, 2008
    Publication date: December 24, 2009
    Inventors: Lyle R. Deobald, John D. Morris, Karl B. Lee, Jeffery L. Marcoe, Mark C. Iden, Christopher G. Harris