Patents by Inventor Jeffrey D. Woods

Jeffrey D. Woods 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: 20250042578
    Abstract: A repair method is provided during which a thermoplastic patch is arranged on a thermoplastic aircraft component. The thermoplastic patch and the thermoplastic aircraft component each include a thermoplastic matrix and a plurality of fibers embedded within the thermoplastic matrix. A metal plate is arranged against a stack. The stack includes the thermoplastic patch and the thermoplastic aircraft component. The thermoplastic patch and the thermoplastic aircraft component are consolidated together. The consolidating includes concurrently induction heating the thermoplastic patch, the thermoplastic aircraft component and the metal plate using an induction heating coil.
    Type: Application
    Filed: July 31, 2023
    Publication date: February 6, 2025
    Inventors: Alfred Y. Tang, Igor Kiyanitsyn, Milan Mitrovic, Michael van Tooren, Jeffrey D. Woods
  • Publication number: 20250033756
    Abstract: A method is provided during which a thermoplastic rib is arranged with a thermoplastic spar. A first flange of the thermoplastic rib is abutted against the thermoplastic spar. The first flange of the thermoplastic rib is ultrasonic welded to the thermoplastic spar using a tilted ultrasonic horn. A centerline of the tilted ultrasonic horn is angularly offset from the first flange of the thermoplastic rib by an acute angle during the ultrasonic welding.
    Type: Application
    Filed: July 28, 2023
    Publication date: January 30, 2025
    Inventors: Shyan Bob Shen, Michael van Tooren, Daniel O. Ursenbach, Jeffrey D. Woods
  • Patent number: 12186996
    Abstract: A welding assembly is disclosed. The welding assembly includes a plurality of separately controllable actuators (e.g., pneumatic, having an axially movable ram) to press a corresponding portion of a first workpiece (e.g., a discrete flange of a first stiffener) against a second workpiece (e.g., an outer skin) for welding operations (e.g., via induction welding).
    Type: Grant
    Filed: January 29, 2024
    Date of Patent: January 7, 2025
    Assignee: ROHR, INC.
    Inventors: Jonathan S. Huang, Michael van Tooren, Dominic J Elliott, Jeffrey D. Woods
  • Publication number: 20250001708
    Abstract: A method for forming a fiber-reinforced thermoplastic part may comprise the steps of locating a lightning strike protection layer on a mold surface of a mold tool, locating a thermoplastic layer over the mold tool, heating the thermoplastic layer to a pliable forming temperature, conforming the thermoplastic layer to a mold surface of the mold tool, and depositing a plurality of fiber strips over the thermoplastic layer.
    Type: Application
    Filed: September 16, 2024
    Publication date: January 2, 2025
    Applicant: ROHR, INC.
    Inventors: Jonathan S. Huang, Jeffrey D. Woods, Michael van Tooren, Noushin Bahramshahi
  • Publication number: 20240391179
    Abstract: A method is provided during which a first thermoplastic composite body is arranged on a rigid support structure. The first thermoplastic composite body contacts the rigid support structure. A second thermoplastic composite body is arranged on the first thermoplastic composite body. The second thermoplastic composite body contacts the first thermoplastic composite body. Energy transmission material is arranged on the second thermoplastic composite body. The first thermoplastic composite body and the second thermoplastic composite body are disposed between the rigid support structure and the energy transmission material. The second thermoplastic composite body is ultrasonic welded to the first thermoplastic composite body using an ultrasonic horn. The energy transmission material is arranged between the second thermoplastic composite body and the ultrasonic horn.
    Type: Application
    Filed: August 18, 2023
    Publication date: November 28, 2024
    Inventors: Michael van Tooren, Shyan Bob Shen, Jeffrey D. Woods, Keith E. Ritchie
  • Patent number: 12115738
    Abstract: A method for forming a fiber-reinforced thermoplastic part may comprise the steps of locating a lightning strike protection layer on a mold surface of a mold tool, locating a thermoplastic layer over the mold tool, heating the thermoplastic layer to a pliable forming temperature, conforming the thermoplastic layer to a mold surface of the mold tool, and depositing a plurality of fiber strips over the thermoplastic layer.
    Type: Grant
    Filed: January 18, 2022
    Date of Patent: October 15, 2024
    Assignee: ROHR, INC.
    Inventors: Jonathan S. Huang, Jeffrey D. Woods, Michael van Tooren, Noushin Bahramshahi
  • Publication number: 20240336020
    Abstract: A method for forming a fiber reinforced thermoplastic part may comprise the steps of locating a thermoplastic material over a mold tool, heating the thermoplastic material to a pliable forming temperature, conforming the thermoplastic material to a mold surface of the mold tool, and depositing a plurality of fiber strips over the thermoplastic material.
    Type: Application
    Filed: June 18, 2024
    Publication date: October 10, 2024
    Applicant: Rohr, Inc.
    Inventors: Michael van Tooren, Jonathan S Huang, Noushin Bahramshahi, Jeffrey D Woods
  • Publication number: 20240253275
    Abstract: A modular tooling arrangement includes a base member comprising a planar working surface, a frame circumscribing a first cavity at least partially defined by the planar working surface, and a plurality of plates configured to be received in the first cavity for forming a second cavity of a desired shape and size. The plurality of plates at least partially define the second cavity configured to receive a work piece. The plurality of plates may be replaced with plates of various sizes to vary at least one of the size and shape of the second cavity.
    Type: Application
    Filed: March 11, 2024
    Publication date: August 1, 2024
    Applicant: ROHR, INC.
    Inventors: JEFFREY D. WOODS, ROBERTO RAMOS, JAVIER LACALLE, ANDREW ADAN
  • Patent number: 12043003
    Abstract: A method for forming a fiber reinforced thermoplastic part may comprise the steps of locating a thermoplastic material over a mold tool, heating the thermoplastic material to a pliable forming temperature, conforming the thermoplastic material to a mold surface of the mold tool, and depositing a plurality of fiber strips over the thermoplastic material.
    Type: Grant
    Filed: January 18, 2022
    Date of Patent: July 23, 2024
    Assignee: ROHR, INC.
    Inventors: Jonathan S. Huang, Jeffrey D. Woods, Michael Van Tooren, Noushin Bahramshahi
  • Publication number: 20240217192
    Abstract: A method for repairing a thermoplastic composite component is provided that includes: preparing at least one repair patch configured to conform with a defect region of the thermoplastic composite component, the defect region having a periphery that defines the defect region, the at least one repair patch comprising a thermoplastic composite material; providing a thermoplastic interface film configured to conform with at least a part of the at least one repair patch, the thermoplastic interface film having a melt temperature; disposing the thermoplastic interface film between a surface of the thermoplastic composite component disposed at the periphery of the defect region and the at least one repair patch; and heating the thermoplastic interface film to its melt temperature using an ultrasonic welder, and subsequently allowing the thermoplastic interface film to cool, thereby welding the at least one repair patch to the thermoplastic composite component.
    Type: Application
    Filed: January 3, 2023
    Publication date: July 4, 2024
    Inventors: Shyan Bob Shen, Michael van Tooren, Jeffrey D. Woods, Shawn Tardy
  • Publication number: 20240217183
    Abstract: A method for joining thermoplastic composite includes: providing a first part having a first joining surface disposed in a first plane and a second joining surface disposed in a second plane that is non-parallel to the first plane; providing a second part having a third joining surface disposed in the first plane and a fourth joining surface disposed in the second plane; disposing the parts so that the first and third joining surfaces are in contact with one another, and the second and fourth joining surfaces are in contact with one another; forcing the second and fourth joining surfaces against one another; and welding the first and third joining surfaces together using a vibration welding process, wherein the welding process and the forcing of the second and fourth joining surfaces against one another causes the second and fourth joining surfaces to be welded.
    Type: Application
    Filed: January 3, 2023
    Publication date: July 4, 2024
    Inventors: Shyan Bob Shen, Michael van Tooren, Jeffrey D. Woods, Alan Phillips
  • Publication number: 20240165892
    Abstract: A welding assembly is disclosed. The welding assembly includes a plurality of separately controllable actuators (e.g., pneumatic, having an axially movable ram) to press a corresponding portion of a first workpiece (e.g., a discrete flange of a first stiffener) against a second workpiece (e.g., an outer skin) for welding operations (e.g., via induction welding).
    Type: Application
    Filed: January 29, 2024
    Publication date: May 23, 2024
    Applicant: ROHR, INC.
    Inventors: Jonathan S. Huang, Michael van Tooren, Dominic J. Elliott, Jeffrey D. Woods
  • Patent number: 11958216
    Abstract: A modular tooling arrangement includes a base member comprising a planar working surface, a frame circumscribing a first cavity at least partially defined by the planar working surface, and a plurality of plates configured to be received in the first cavity for forming a second cavity of a desired shape and size. The plurality of plates at least partially define the second cavity configured to receive a work piece. The plurality of plates may be replaced with plates of various sizes to vary at least one of the size and shape of the second cavity.
    Type: Grant
    Filed: December 17, 2021
    Date of Patent: April 16, 2024
    Assignee: ROHR, INC.
    Inventors: Jeffrey D. Woods, Roberto Ramos, Javier Lacalle, Andrew Adan
  • Publication number: 20240109644
    Abstract: A manufacturing method is provided. A first end of a set of spars is coupled to a first skin of a flight control surface. A set of ribs is interlocked with the set of spars and a first end of the set of ribs is coupled to the first skin. A second skin is coupled to a second end of the set of spars and a second end of the set of ribs.
    Type: Application
    Filed: July 21, 2023
    Publication date: April 4, 2024
    Applicant: Rohr, Inc.
    Inventors: Liam Carmody, Justin Ngo, Milena Salazar, Shyan Bob Shen, Jeffrey D. Woods
  • Patent number: 11919253
    Abstract: A welding assembly is disclosed. The welding assembly includes a plurality of separately controllable actuators (e.g., pneumatic, having an axially movable ram) to press a corresponding portion of a first workpiece (e.g., a discrete flange of a first stiffener) against a second workpiece (e.g., an outer skin) for welding operations (e.g., via induction welding).
    Type: Grant
    Filed: July 21, 2022
    Date of Patent: March 5, 2024
    Assignee: ROHR, INC.
    Inventors: Jonathan S. Huang, Michael van Tooren, Dominic J Elliott, Jeffrey D. Woods
  • Publication number: 20240025129
    Abstract: A welding assembly is disclosed. The welding assembly includes a plurality of separately controllable actuators (e.g., pneumatic, having an axially movable ram) to press a corresponding portion of a first workpiece (e.g., a discrete flange of a first stiffener) against a second workpiece (e.g., an outer skin) for welding operations (e.g., via induction welding).
    Type: Application
    Filed: July 21, 2022
    Publication date: January 25, 2024
    Applicant: ROHR, INC.
    Inventors: Jonathan S. Huang, Michael van Tooren, Dominic J. Elliott, Jeffrey D. Woods
  • Patent number: 11865791
    Abstract: During a manufacturing method, an induction welder is provided that includes a concentrator and a coil extending through a receptacle in the concentrator. The receptacle projects into the concentrator from a face surface of the concentrator. A first thermoplastic body arranged with a second thermoplastic body are provided. The first thermoplastic body is located next to the face surface. The first thermoplastic body is induction welded to the second thermoplastic body to provide a weld seam between the first thermoplastic body and the second thermoplastic body. The concentrator extends along a portion of the weld seam. The induction welding includes: generating an electromagnetic field with the coil; and concentrating a portion of the electromagnetic field with the concentrator onto a region of the first thermoplastic body.
    Type: Grant
    Filed: December 30, 2021
    Date of Patent: January 9, 2024
    Assignee: Rohr, Inc.
    Inventors: Jonathan S. Huang, Michael van Tooren, Jeffrey D. Woods
  • Publication number: 20230381883
    Abstract: An assembly is provided for induction welding. This assembly utilizes a plurality of heat shields (e.g., mica heat shields) that are aligned/disposed in end-to-end relation, with each such heat shield having a recess. An induction welding coil may be disposed within a heat shield recess during induction welding operations and is movable along a welding path while proceeding along the recesses of the various heat shields. This welding path may be axially extending or may be curved. The induction welding assembly may be used to induction weld a stiffener to a curved skin or shell, for instance where a base of the recess for each heat shield is curved such that the induction welding coil may be moved along a curved welding path and while maintaining a constant spacing between the induction welding coil and the recess base of the various heat shields.
    Type: Application
    Filed: May 24, 2022
    Publication date: November 30, 2023
    Applicant: ROHR, INC.
    Inventors: Robert Lechner, Jeffrey D. Woods, Jonathan S. Huang, Michael van Tooren
  • Publication number: 20230381884
    Abstract: An assembly is provided for induction welding. This assembly utilizes a heat shield (e.g., a mica heat shield) with a recess. An induction welding coil may be disposed within this heat shield recess during induction welding operations. The wall thickness of the heat shield within the recess may be reduced to enhance heat transfer to a workpiece during induction welding operations. The heat shield may be coated with a ceramic coating to enhance the heat shield's heat resistance and reduce heat shield flaking at the recess during induction welding operations.
    Type: Application
    Filed: May 24, 2022
    Publication date: November 30, 2023
    Applicant: Rohr, Inc.
    Inventors: MICHAEL VAN TOOREN, JEFFREY D. WOODS
  • Patent number: 11760036
    Abstract: An induction welding system includes a first gantry, a second gantry, and a support structure. The first gantry includes a first frame and a first plurality of trunks. The first plurality of trunks defines a first curved inner support surface of the first gantry. The first curved inner support surface has a first curvature geometry. The second gantry includes a second frame and a second plurality of trunks. The second plurality of trunks defines a second curved inner support surface of the second gantry. The second curved inner support surface has a second curvature geometry which is different than the first curvature geometry. The support structure includes at least one tooling member defining a curved outer support surface of the support structure. The support structure is longitudinally moveable relative to the first gantry and the second gantry.
    Type: Grant
    Filed: December 17, 2021
    Date of Patent: September 19, 2023
    Assignee: Rohr, Inc.
    Inventors: Jonathan S. Huang, Jeffrey D. Woods, Andrew Adan, Robert Lechner