Patents by Inventor Joel James Everhart
Joel James Everhart 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: 9073240Abstract: A method and support apparatus for providing structural support to a mold or mandrel, such as a shape memory polymer (SMP) apparatus configured for shaping a composite part. The support apparatus may comprise a rigid structural member and a plurality of SMP cells attached thereto and configured to inflate or deploy in a malleable state toward and against a surface of the SMP apparatus, mold, or mandrel. Then the SMP cells may be returned to a rigid state while still pressed against this surface, thereby providing structural support when composite material is applied to an opposite surface of the SMP apparatus, mold, or mandrel. After the composite material is cured into the finished composite part, the SMP cells may be deflated or otherwise collapse toward the structural member to provide enough clearance to be removed from the cured composite part.Type: GrantFiled: September 27, 2011Date of Patent: July 7, 2015Assignee: Spirit AeroSystems, Inc.Inventors: Scott Robert Huelskamp, Joel James Everhart, David E. Havens, Steven Fillmore Hanson, Jeffrey W. Priest, Carl Ray Fiegenbaum, Thomas Joseph Barnell
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Patent number: 8974217Abstract: A method and support apparatus for providing structural support to a mold or mandrel, such as a shape memory polymer (SMP) apparatus configured for shaping a composite part. The support apparatus may comprise a rigid structural member and a plurality of SMP cells attached thereto and configured to inflate or deploy in a malleable state toward and against a surface of the SMP apparatus, mold, or mandrel. Then the SMP cells may be returned to a rigid state while still pressed against this surface, thereby providing structural support when composite material is applied to an opposite surface of the SMP apparatus, mold, or mandrel. After the composite material is cured into the finished composite part, the SMP cells may be deflated or otherwise collapse toward the structural member to provide enough clearance to be removed from the cured composite part.Type: GrantFiled: September 27, 2011Date of Patent: March 10, 2015Assignee: Spirit AeroSystems, Inc.Inventors: Joel James Everhart, Bryan Michael Pelley, David E Havens, Steven Fillmore Hanson, Jeffrey W. Priest, Carl Ray Fiegenbaum
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Patent number: 8945455Abstract: A support apparatus and method for providing structural support to a shape memory polymer (SMP) apparatus during fabrication of composite parts. The support apparatus may comprise an adjustable, rigid structural member and a plurality of SMP support components transitionable between a rigid and malleable state and fixed to an outer surface of the rigid structural member. The rigid structural member may extend in at least one cross-sectional dimension toward the SMP apparatus, pressing the SMP support components, in their malleable state, against the SMP apparatus. The SMP support components may thereby conform to a first surface of the SMP apparatus, then return to their rigid state while pressed against the SMP apparatus, thus providing a rigid load path between the SMP apparatus and the rigid structural member. Then composite material may be applied to a second surface of the SMP apparatus, opposite of the first surface.Type: GrantFiled: November 3, 2011Date of Patent: February 3, 2015Assignee: Spirit AeroSystems, Inc.Inventors: Joel James Everhart, Thomas Wood Margraf, David E. Havens
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Patent number: 8815145Abstract: A method and apparatus for fabricating a composite part with a shape memory polymer (SMP) apparatus usable as both a rigid tool and as a bladder. The SMP apparatus may be heated until malleable, shaped, and then cooled in a desired rigid tool configuration. The composite material may be applied onto the SMP apparatus and then placed into a rigid external mold and heated to composite cure temperatures at which the SMP apparatus is malleable. In some embodiments, an impermeable sheet of material may also be placed over portions of the composite material to compress it against the SMP apparatus. A pressure differential may be induced which urges the SMP apparatus to compress the composite material against the rigid external mold. When the composite material is cured, the pressure differential may be equalized and/or reversed and the malleable SMP apparatus may be removed from within the composite part.Type: GrantFiled: September 21, 2011Date of Patent: August 26, 2014Assignee: Spirit AeroSystems, Inc.Inventors: Matthew C. Everhart, David E. Havens, Joel James Everhart, Randy Rex Kysar, Carl Ray Fiegenbaum, Jeffrey W. Priest, Kevin John Ford, Delbert Leon Strelow
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Patent number: 8734703Abstract: A method and apparatus for fabricating a composite part with a shape memory polymer (SMP) apparatus usable as both a rigid lay-up tool and as a bladder. The SMP apparatus may be heated until malleable, shaped, and then cooled in a desired rigid tool configuration. For example, cavities may be formed into the SMP apparatus for nesting components therein to co-bond or co-cure with the composite part. The composite material may be applied onto the SMP apparatus in the rigid tool configuration and then placed into a rigid external tool and heated to composite cure temperatures at which the SMP apparatus is malleable. A pressure differential may be induced which urges the SMP apparatus to compress the composite material against the rigid external tool. When the composite material is cured, the SMP apparatus may be urged away from the cure composite material and removed from within the composite part.Type: GrantFiled: September 21, 2011Date of Patent: May 27, 2014Assignee: Spirit AeroSystems, Inc.Inventors: David E. Havens, Matthew C. Everhart, Thomas Wood Margraf, Joel James Everhart, Randy Rex Kysar, Carl Ray Fiegenbaum, Jeffrey W. Priest, Delbert Leon Strelow, Kristin Dru Pickell
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Patent number: 8608890Abstract: A method and support apparatus for providing structural support to a mold or mandrel, such as a shape memory polymer (SMP) apparatus configured for shaping a composite part. The support apparatus may comprise a rigid structural member and a plurality of SMP cells attached thereto and configured to inflate or deploy in a malleable state toward and against a surface of the SMP apparatus, mold, or mandrel. Then the SMP cells may be returned to a rigid state while still pressed against this surface, thereby providing structural support when composite material is applied to an opposite surface of the SMP apparatus, mold, or mandrel. After the composite material is cured into the finished composite part, the SMP cells may be deflated or otherwise collapse toward the structural member to provide enough clearance to be removed from the cured composite part.Type: GrantFiled: September 27, 2011Date of Patent: December 17, 2013Assignee: Spirit AeroSystems, Inc.Inventors: Joel James Everhart, David E. Havens, Steven Fillmore Hanson, Jeffrey W. Priest, Carl Ray Fiegenbaum, Thomas Joseph Barnell
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Publication number: 20120286457Abstract: A method and apparatus for fabricating a composite part with a shape memory polymer (SMP) apparatus usable as both a rigid tool and as a bladder. The SMP apparatus may be heated until malleable, shaped, and then cooled in a desired rigid tool configuration. The composite material may be applied onto the SMP apparatus and then placed into a rigid external mold and heated to composite cure temperatures at which the SMP apparatus is malleable. In some embodiments, an impermeable sheet of material may also be placed over portions of the composite material to compress it against the SMP apparatus. A pressure differential may be induced which urges the SMP apparatus to compress the composite material against the rigid external mold. When the composite material is cured, the pressure differential may be equalized and/or reversed and the malleable SMP apparatus may be removed from within the composite part.Type: ApplicationFiled: September 21, 2011Publication date: November 15, 2012Applicant: SPIRIT AEROSYSTEMS, INC.Inventors: Matthew C. Everhart, David E. Havens, Joel James Everhart, Randy Rex Kysar, Carl Ray Fiegenbaum, Jeffrey W. Priest, Kevin John Ford, Delbert Leon Strelow
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Publication number: 20120288655Abstract: A method and apparatus for fabricating a composite part with a shape memory polymer (SMP) apparatus usable as both a rigid lay-up tool and as a bladder. The SMP apparatus may be heated until malleable, shaped, and then cooled in a desired rigid tool configuration. For example, cavities may be formed into the SMP apparatus for nesting components therein to co-bond or co-cure with the composite part. The composite material may be applied onto the SMP apparatus in the rigid tool configuration and then placed into a rigid external tool and heated to composite cure temperatures at which the SMP apparatus is malleable. A pressure differential may be induced which urges the SMP apparatus to compress the composite material against the rigid external tool. When the composite material is cured, the SMP apparatus may be urged away from the cure composite material and removed from within the composite part.Type: ApplicationFiled: September 21, 2011Publication date: November 15, 2012Applicant: Spirit AeroSystems, Inc.Inventors: David E. Havens, Matthew C. Everhart, Thomas Wood Margraf, Joel James Everhart, Randy Rex Kysar, Carl Ray Fiegenbaum, Jeffrey W. Priest, Delbert Leon Strelow, Kristin Dru Pickell
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Publication number: 20120119417Abstract: A method and support apparatus for providing structural support to a mold or mandrel, such as a shape memory polymer (SMP) apparatus configured for shaping a composite part. The support apparatus may comprise a rigid structural member and a plurality of SMP cells attached thereto and configured to inflate or deploy in a malleable state toward and against a surface of the SMP apparatus, mold, or mandrel. Then the SMP cells may be returned to a rigid state while still pressed against this surface, thereby providing structural support when composite material is applied to an opposite surface of the SMP apparatus, mold, or mandrel. After the composite material is cured into the finished composite part, the SMP cells may be deflated or otherwise collapse toward the structural member to provide enough clearance to be removed from the cured composite part.Type: ApplicationFiled: September 27, 2011Publication date: May 17, 2012Applicant: SPIRIT AEROSYSTEMS, INC.Inventors: Joel James Everhart, Bryan Michael Pelley, David E. Havens, Steven Fillmore Hanson, Jeffrey W. Priest, Carl Ray Fiegenbaum
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Publication number: 20120118491Abstract: A method and support apparatus for providing structural support to a mold or mandrel, such as a shape memory polymer (SMP) apparatus configured for shaping a composite part. The support apparatus may comprise a rigid structural member and a plurality of SMP cells attached thereto and configured to inflate or deploy in a malleable state toward and against a surface of the SMP apparatus, mold, or mandrel. Then the SMP cells may be returned to a rigid state while still pressed against this surface, thereby providing structural support when composite material is applied to an opposite surface of the SMP apparatus, mold, or mandrel. After the composite material is cured into the finished composite part, the SMP cells may be deflated or otherwise collapse toward the structural member to provide enough clearance to be removed from the cured composite part.Type: ApplicationFiled: September 27, 2011Publication date: May 17, 2012Applicant: SPIRIT AEROSYSTEMS, INC.Inventors: Joel James Everhart, David E. Havens, Steven Fillmore Hanson, Jeffrey W. Priest, Carl Ray Fiegenbaum
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Publication number: 20120119416Abstract: A method and support apparatus for providing structural support to a mold or mandrel, such as a shape memory polymer (SMP) apparatus configured for shaping a composite part. The support apparatus may comprise a rigid structural member and a plurality of SMP cells attached thereto and configured to inflate or deploy in a malleable state toward and against a surface of the SMP apparatus, mold, or mandrel. Then the SMP cells may be returned to a rigid state while still pressed against this surface, thereby providing structural support when composite material is applied to an opposite surface of the SMP apparatus, mold, or mandrel. After the composite material is cured into the finished composite part, the SMP cells may be deflated or otherwise collapse toward the structural member to provide enough clearance to be removed from the cured composite part.Type: ApplicationFiled: September 27, 2011Publication date: May 17, 2012Applicant: SPIRIT AEROSYSTEMS, INC.Inventors: Scott Robert Huelskamp, Joel James Everhart, David E. Havens, Steven Fillmore Hanson, Jeffrey W. Priest, Carl Ray Fiegenbaum
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Publication number: 20120119411Abstract: A support apparatus and method for providing structural support to a shape memory polymer (SMP) apparatus during fabrication of composite parts. The support apparatus may comprise an adjustable, rigid structural member and a plurality of SMP support components transitionable between a rigid and malleable state and fixed to an outer surface of the rigid structural member. The rigid structural member may extend in at least one cross-sectional dimension toward the SMP apparatus, pressing the SMP support components, in their malleable state, against the SMP apparatus. The SMP support components may thereby conform to a first surface of the SMP apparatus, then return to their rigid state while pressed against the SMP apparatus, thus providing a rigid load path between the SMP apparatus and the rigid structural member. Then composite material may be applied to a second surface of the SMP apparatus, opposite of the first surface.Type: ApplicationFiled: November 3, 2011Publication date: May 17, 2012Applicant: SPIRIT AEROSYSTEMS, INC.Inventors: Joel James Everhart, Thomas Wood Margraf, David E. Havens
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Publication number: 20090095865Abstract: A device utilizing the unique properties of shape memory materials to securely hold items of varying geometric shape and size securely in place is disclosed. This device and process works equally well for securely holding in place small items, such as would be stored in a cup holder, or for securely larger items in a cargo container. By deforming the shape memory material such that it conforms to the outer dimensions of the item to be held in place a secure and tight fit is assured.Type: ApplicationFiled: May 1, 2007Publication date: April 16, 2009Applicant: CORNERSTONE RESEARCH GROUP, INC.Inventors: Joel James Everhart, David Ernest Havens, Thomas Wood Margraf