Patents by Inventor Joseph D. Brennan

Joseph D. Brennan 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: 8568551
    Abstract: A pre-patterned layup kit with layup patterned to accommodate an airframe topological feature, trimmed to fit a preselected target region of a layup structure, and conformed to the target region contour. The kit can be fabricated in advance of airframe manufacture and stored until use. The kit includes a flexible carrier upon which the layup is laid, and a release layer between the layup and the carrier. The layup has multiple laminae oriented to an carrier indexing element, and indexed to the target region thereby. A kit manufacturing method includes preparing the laminae constituent of the layup, preparing the carrier, and laying down the laminae on the carrier to make the kit. The kit can be compacted, inspected, and prepared for storage. The layup can be fabricated of a pre-patterned lamina or multiple laminae that are shaped and trimmed to accommodate an airframe topological feature.
    Type: Grant
    Filed: May 22, 2007
    Date of Patent: October 29, 2013
    Assignee: The Boeing Company
    Inventors: Joseph D. Brennan, George D. Hempstead, Darrell D. Jones, Matthew K. Lum, Peter D. McCowin, Terrence J. Rowe, Hugh R. Schlosstein
  • Patent number: 8557165
    Abstract: A method of forming a flat composite charge into a contoured composite part reduces wrinkles in the part as the charge is being formed. Dies are used to form a portion of charge to the steepest contour of the part, while tension is maintained on the charge as the remaining portions of the charge are formed.
    Type: Grant
    Filed: October 25, 2008
    Date of Patent: October 15, 2013
    Assignee: The Boeing Company
    Inventors: Darrell D. Jones, Michael A. Lee, Michael R. Anderson, Joseph D. Brennan
  • Patent number: 8454870
    Abstract: A method for manufacturing composite parts. A temporary removal layer may be placed on an inner mold line tool. A composite material may be laid up on the inner mold line tool for a composite part. The inner mold line tool may be positioned with the composite part inside an outer mold line tool. The composite part and the temporary removal layer may be transferred from the inner mold line tool to the outer mold line tool. The inner mold line tool and the temporary removal layer may be removed from inside of the outer mold line tool after transferring the composite part and the temporary removal layer to the outer mold line tool.
    Type: Grant
    Filed: December 19, 2008
    Date of Patent: June 4, 2013
    Assignee: The Boeing Company
    Inventors: William S. Hollensteiner, Joseph D. Brennan, Jennifer Sue Noel, Kurtis Shuldberg Willden, Daniel M. Rotter, Shane Edward Arthur, Brian G. Robins, Darrell D. Jones
  • Patent number: 8333864
    Abstract: A flexible compaction sheet is used to compact uncured composite plies onto the surface of a ply layup. The compaction sheet includes a peripheral seal that seals the perimeter of the sheet to the surface of the part layup and forms a vacuum chamber over the plies which is evacuated through the sheet to apply compaction pressure to the plies.
    Type: Grant
    Filed: September 30, 2008
    Date of Patent: December 18, 2012
    Assignee: The Boeing Company
    Inventors: Joseph D. Brennan, Travis J. Sherwood
  • Publication number: 20120261059
    Abstract: A structural filler is installed in a gap between at least first and second composite members by extruding a flowable filler material, placing the extruded filler on one of the composite structural members, and assembling the composite members.
    Type: Application
    Filed: June 15, 2012
    Publication date: October 18, 2012
    Applicant: THE BOEING COMPANY
    Inventors: Travis J. Sherwood, Brian G. Robins, Darrell D. Jones, Joseph D. Brennan, Michael R. Anderson
  • Patent number: 8216499
    Abstract: A structural filler is installed in a gap between at least first and second composite members by extruding a flowable filler material, placing the extruded filler on one of the composite structural members, and assembling the composite members.
    Type: Grant
    Filed: December 9, 2008
    Date of Patent: July 10, 2012
    Assignee: The Boeing Company
    Inventors: Travis J. Sherwood, Brian G. Robins, Darrell D. Jones, Joseph D. Brennan, Michael R. Anderson
  • Publication number: 20100155984
    Abstract: A method for manufacturing composite parts. A temporary removal layer may be placed on an inner mold line tool. A composite material may be laid up on the inner mold line tool for a composite part. The inner mold line tool may be positioned with the composite part inside an outer mold line tool. The composite part and the temporary removal layer may be transferred from the inner mold line tool to the outer mold line tool. The inner mold line tool and the temporary removal layer may be removed from inside of the outer mold line tool after transferring the composite part and the temporary removal layer to the outer mold line tool.
    Type: Application
    Filed: December 19, 2008
    Publication date: June 24, 2010
    Inventors: William S. Hollensteiner, Joseph D. Brennan, Jennifer Sue Noel, Kurtis Shuldberg Willden, Daniel M. Rotter, Shane Edward Arthur, Brian G. Robins, Darrell D. Jones
  • Publication number: 20100154990
    Abstract: A method and apparatus for manufacturing composite parts. An expandable tool with a transfer system may be moved on a surface of the expandable tool into an outer mold line tool with a composite material laid up on the outer mold line tool. The expandable tool may be expanded in the outer mold line tool to change the surface from a retracted state to an expanded state. The transfer system may be transferred from the expandable tool with the surface in the expanded state to the outer mold line tool.
    Type: Application
    Filed: December 19, 2008
    Publication date: June 24, 2010
    Inventors: Joseph D. Brennan, Donald Chester Darrow, Kenneth M. Dull, William S. Hollensteiner, Jennifer Sue Noel
  • Publication number: 20100140834
    Abstract: A structural filler is installed in a gap between at least first and second composite members by extruding a flowable filler material, placing the extruded filler on one of the composite structural members, and assembling the composite members.
    Type: Application
    Filed: December 9, 2008
    Publication date: June 10, 2010
    Inventors: Travis J. Sherwood, Brian G. Robins, Darrell D. Jones, Joseph D. Brennan, Michael R. Anderson
  • Publication number: 20100102482
    Abstract: A method of forming a flat composite charge into a contoured composite part reduces wrinkles in the part as the charge is being formed. Dies are used to form a portion of charge to the steepest contour of the part, while tension is maintained on the charge as the remaining portions of the charge are formed.
    Type: Application
    Filed: October 25, 2008
    Publication date: April 29, 2010
    Inventors: Darrell D. Jones, Michael A. Lee, Michael R. Anderson, Joseph D. Brennan
  • Publication number: 20100078126
    Abstract: A flexible compaction sheet is used to compact uncured composite plies onto the surface of a ply layup. The compaction sheet includes a peripheral seal that seals the perimeter of the sheet to the surface of the part layup and forms a vacuum chamber over the plies which is evacuated through the sheet to apply compaction pressure to the plies.
    Type: Application
    Filed: September 30, 2008
    Publication date: April 1, 2010
    Inventors: Joseph D. Brennan, Travis J. Sherwood
  • Publication number: 20100068326
    Abstract: Tools for manufacturing composite parts and methods for using such tools are disclosed herein. A method in accordance with one aspect of the invention includes manufacturing a fiber-reinforced resin part from a plurality of fibers positioned on a tool having a female mold surface. The mold surface can include a first side region, a second side region, an interior region between the first and second side regions, and transition regions between the first and second side regions and the interior region. The method includes positioning a compaction tool over the mold surface. The compaction tool includes a first pressing device and a second pressing device carrying the first pressing device. The method further includes pressing a first portion of the fibers against the transition regions with the first pressing device without generally compacting the portions of the fibers outboard of the transition regions.
    Type: Application
    Filed: November 23, 2009
    Publication date: March 18, 2010
    Applicant: THE BOEING COMPANY
    Inventors: Darrell D. Jones, Joseph D. Brennan, Mark W. King, Kurtis S. Willden, George D. Hempstead
  • Patent number: 7655168
    Abstract: Tools for manufacturing composite parts and methods for using such tools are disclosed herein. A method in accordance with one aspect of the invention includes manufacturing a fiber-reinforced resin part from a plurality of fibers positioned on a tool having a female mold surface. The mold surface can include a first side region, a second side region, an interior region between the first and second side regions, and transition regions between the first and second side regions and the interior region. The method includes positioning a compaction tool over the mold surface. The compaction tool includes a first pressing device and a second pressing device carrying the first pressing device. The method further includes pressing a first portion of the fibers against the transition regions with the first pressing device without generally compacting the portions of the fibers outboard of the transition regions.
    Type: Grant
    Filed: January 31, 2006
    Date of Patent: February 2, 2010
    Assignee: The Boeing Company
    Inventors: Darrell D. Jones, Joseph D. Brennan, Mark E. King, Kurtis S. Willden, George D. Hempstead
  • Publication number: 20100012260
    Abstract: A pre-patterned layup kit with layup patterned to accommodate an airframe topological feature, trimmed to fit a preselected target region of a layup structure, and conformed to the target region contour. The kit can be fabricated in advance of airframe manufacture and stored until use. The kit includes a flexible carrier upon which the layup is laid, and a release layer between the layup and the carrier. The layup has multiple laminae oriented to an carrier indexing element, and indexed to the target region thereby. A kit manufacturing method includes preparing the laminae constituent of the layup, preparing the carrier, and laying down the laminae on the carrier to make the kit. The kit can be compacted, inspected, and prepared for storage. The layup can be fabricated of a pre-patterned lamina or multiple laminae that are shaped and trimmed to accommodate an airframe topological feature.
    Type: Application
    Filed: May 22, 2007
    Publication date: January 21, 2010
    Inventors: Joseph D. Brennan, George D. Hempstead, Darrell D. Jones, Matthew K. Lum, Peter D. McCowin, Terrence J. Rowe, Hugh R. Schlosstein
  • Publication number: 20100011580
    Abstract: Method and apparatus for layup placement on a layup structure is provided. The method includes iteratively loading a layup for the layup structure on a support frame of a saddle module; aligning the saddle module with a pre-selected registration position corresponding to a predetermined application path on the layup structure; and impressing the layup into forced contact with the layup structure along the predetermined application path using a predetermined application force. The apparatus includes a plurality of saddle modules configured to operate in unison, wherein the plurality of saddle modules is configured to receive a pre-selected composite material layup.
    Type: Application
    Filed: May 22, 2007
    Publication date: January 21, 2010
    Inventors: Joseph D. Brennan, George D. Hempstead, Darrell D. Jones, Matthew K. Lum, Peter D. McCowin, Terrence J. Rowe, Hugh R. Schlosstein
  • Publication number: 20090320292
    Abstract: A hands-free method and related apparatus are used to shape, place and compact a composite stringer on a composite skin of an aircraft. A composite charge is placed on a tool assembly that used to shape the charge into a preformed stringer. With the stringer held on the tool assembly, the tool assembly is used to move the preformed stringer into proximity with the skin and both place and compact the stringer against the skin. Following compaction of the stringer, the tool assembly is removed and the skin and the stringer are co-cured.
    Type: Application
    Filed: June 13, 2008
    Publication date: December 31, 2009
    Inventors: Joseph D. Brennan, Darrell D. Jones, Brian G. Robins
  • Publication number: 20090145545
    Abstract: A modular composite manufacturing method. An illustrative embodiment of the method includes providing a plurality of composite modules; inspecting the composite modules; providing a curing tool; and placing the composite modules on the curing tool.
    Type: Application
    Filed: December 7, 2007
    Publication date: June 11, 2009
    Inventors: Joseph D. Brennan, Darrell D. Jones, Kurtis S. Willden
  • Publication number: 20090148647
    Abstract: A large scale composite structure is fabricated by forming a plurality of composite laminate modules and joining the modules together along their edges using scarf joints.
    Type: Application
    Filed: August 28, 2008
    Publication date: June 11, 2009
    Inventors: Darrell D. Jones, Arvid J. Berg, Joseph D. Brennan, Travis J. Sherwood