Patents by Inventor Kurtis Willden
Kurtis Willden 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: 11964442Abstract: The disclosed forming apparatus includes a frame. The frame defines a vertical axis, a horizontal axis, and a longitudinal axis. A carriage is movably connected to the frame. A first stomp foot is movably connected to the carriage such that it may move along the vertical axis. A first end effector is movably connected to the carriage. The first end effector is controlled by an actuator. The disclosed method for forming a composite part includes applying at least one ply of composite material over a forming surface of a forming tool and deforming the at least one ply of composite material over the forming surface of the forming tool with a forming apparatus.Type: GrantFiled: October 27, 2021Date of Patent: April 23, 2024Assignee: The Boeing CompanyInventors: Scott Krajca, Long Ly, Chace Wilcoxson, Darrell Jones, Kurtis Willden, Michael A. Lee, Josiah Brubaker, Michael Karas, Joseph Warren, Pavel Lesovoy
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Patent number: 11826970Abstract: A forming apparatus includes a frame. The frame defines a vertical axis, a horizontal axis, and a longitudinal axis. A carriage is movably connected to the frame. A stomp foot is movably connected to the carriage such that it may move along the vertical axis. A first end effector is movably connected to the carriage and a second end effector movably connected to the carriage. The first end effector and second end effector are laterally opposed to each other along the longitudinal axis and the stomp foot is located between the first end effector and the second end effector.Type: GrantFiled: October 20, 2021Date of Patent: November 28, 2023Assignee: The Boeing CompanyInventors: Long Ly, Chace Wilcoxson, Darrell Jones, Kurtis Willden, Michael A. Lee, Jonathan Santiago, Josiah Brubaker, Michael Karas, Joseph Warren
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Patent number: 11685128Abstract: A system for fabricating a composite structure includes a ply carrier including a ply support surface configured to support at least one composite ply. The system includes a carrier transfer device configured to convey the ply carrier. The system includes a lamination system configured to selectively apply the at least one composite ply to the ply support surface of the ply carrier. The system includes a transfer system configured to remove the ply carrier from the carrier transfer device and to apply the at least one composite ply to at least a portion of a forming surface of a forming tool. The system includes a forming system configured to form the at least one composite ply over the at least a portion of the forming surface of the forming tool.Type: GrantFiled: November 1, 2021Date of Patent: June 27, 2023Assignee: The Boeing CompanyInventors: Scott Krajca, Long Ly, Chace Wilcoxson, Darrell Jones, Kurtis Willden, Gregory Klempel, Jeremy Justice, Daniel Smith, Marko Oviir, Mark Bunker, Erik Lund, Wade Morris
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Publication number: 20220176654Abstract: A forming apparatus comprises a frame. The frame defines a vertical axis, a horizontal axis, and a longitudinal axis. A carriage is movably connected to the frame. A first stomp foot is movably connected to the carriage such that it may move along the vertical axis. A second stomp foot is movably connected to the carriage such that it may move along the vertical axis. A first swing arm is movably connected to the carriage and a second swing arm, movably connected to the carriage, is laterally opposed from the first swing arm relative to the longitudinal axis. A method includes applying at least one ply of composite material over a forming surface of a forming tool and deforming the at least one ply of composite material over the forming surface of the forming tool with the forming apparatus.Type: ApplicationFiled: October 20, 2021Publication date: June 9, 2022Applicant: The Boeing CompanyInventors: Scott Krajca, Long Ly, Chace Wilcoxson, Darrell Jones, Kurtis Willden, Michael A. Lee, Josiah Brubaker, Michael Karas, Joseph Warren, Paul Lesovoy
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Publication number: 20220176655Abstract: A forming apparatus includes a frame. The frame defines a vertical axis, a horizontal axis, and a longitudinal axis. A carriage is movably connected to the frame. A stomp foot is movably connected to the carriage such that it may move along the vertical axis. A first end effector is movably connected to the carriage and a second end effector movably connected to the carriage. The first end effector and second end effector are laterally opposed to each other along the longitudinal axis and the stomp foot is located between the first end effector and the second end effector.Type: ApplicationFiled: October 20, 2021Publication date: June 9, 2022Applicant: The Boeing CompanyInventors: Long Ly, Chace Wilcoxson, Darrell Jones, Kurtis Willden, Michael A. Lee, Jonathan Santiago, Josiah Brubaker, Michael Karas, Joseph Warren
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Publication number: 20220176649Abstract: A system for fabricating a composite structure includes a ply carrier including a ply support surface configured to support at least one composite ply. The system includes a carrier transfer device configured to convey the ply carrier. The system includes a lamination system configured to selectively apply the at least one composite ply to the ply support surface of the ply carrier. The system includes a transfer system configured to remove the ply carrier from the carrier transfer device and to apply the at least one composite ply to at least a portion of a forming surface of a forming tool. The system includes a forming system configured to form the at least one composite ply over the at least a portion of the forming surface of the forming tool.Type: ApplicationFiled: November 1, 2021Publication date: June 9, 2022Applicant: The Boeing CompanyInventors: Scott Krajca, Long Ly, Chace Wilcoxson, Darrell Jones, Kurtis Willden, Gregory Klempel, Jeremy Justice, Daniel Smith, Marko Oviir, Mark Bunker, Erik Lund, Wade Morris
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Publication number: 20220176648Abstract: The disclosed forming apparatus includes a frame. The frame defines a vertical axis, a horizontal axis, and a longitudinal axis. A carriage is movably connected to the frame. A first stomp foot is movably connected to the carriage such that it may move along the vertical axis. A first end effector is movably connected to the carriage. The first end effector is controlled by an actuator. The disclosed method for forming a composite part includes applying at least one ply of composite material over a forming surface of a forming tool and deforming the at least one ply of composite material over the forming surface of the forming tool with a forming apparatus.Type: ApplicationFiled: October 27, 2021Publication date: June 9, 2022Applicant: The Boeing CompanyInventors: Scott Krajca, Long Ly, Chace Wilcoxson, Darrell Jones, Kurtis Willden, Michael A. Lee, Josiah Brubaker, Michael Karas, Joseph Warren, Pavel Lesovoy
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Patent number: 10889072Abstract: The present disclosure is directed to a method of making a composite part. The method comprises covering a mold tool for a composite part with a parting film. The method further comprises laying up at least one layer of pre-preg on the parting film covering the mold tool to form a laid-up composite part and removing the laid-up composite part from the parting film. The parting film comprises a polymer sheet having a first major surface and a second major surface; and a first adhesive disposed on the first major surface of the polymer sheet, the first adhesive adhering the polymer sheet to the mold tool.Type: GrantFiled: June 3, 2019Date of Patent: January 12, 2021Assignee: The Boeing CompanyInventors: Hardik Dalal, Alain A. Adjorlolo, Adam F. Gross, Andrew P. Nowak, Brad Andrew Coxon, Kurtis Willden, Daniel M. Rotter, Stephen Lee Metschan, Berryinne Decker
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Publication number: 20190283341Abstract: The present disclosure is directed to a method of making a composite part. The method comprises covering a mold tool for a composite part with a parting film. The method further comprises laying up at least one layer of pre-preg on the parting film covering the mold tool to form a layed-up composite part and removing the layed-up composite part from the parting film. The parting film comprises a polymer sheet having a first major surface and a second major surface; and a first adhesive disposed on the first major surface of the polymer sheet, the first adhesive adhering the polymer sheet to the mold tool.Type: ApplicationFiled: June 3, 2019Publication date: September 19, 2019Applicant: The Boeing CompanyInventors: Hardik Dalal, Alain A. Adjorlolo, Adam F. Gross, Andrew P. Nowak, Brad Andrew Coxon, Kurtis Willden, Daniel M. Rotter, Stephen Lee Metschan, Berryinne Decker
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Patent number: 10308000Abstract: A method of making a composite part comprises covering a mold tool for a composite part with a parting film, the parting film comprising a polymer sheet and a pressure sensitive adhesive. The parting film is positioned so that the polymer sheet is between the mold tool and the pressure sensitive adhesive. At least one layer of pre-preg is layed up on the parting film covering the mold tool to form a layed-up composite part. The pre-preg comprises an adhesive. The layed-up composite part is removed from the parting film.Type: GrantFiled: May 24, 2016Date of Patent: June 4, 2019Assignee: The Boeing CompanyInventors: Hardik Dalal, Alain A. Adjorlolo, Adam F. Gross, Elena M. Sherman, John J. Vajo, Andrew P. Nowak, Brad Andrew Coxon, Kurtis Willden, Daniel M. Rotter, Stephen Lee Metschan, Berryinne Decker
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Patent number: 9994008Abstract: System and method for compacting a composite ply layup comprising a forming tool comprising a top surface and a composite ply layup laid up along the top surface of the forming tool. A single release film comprising a top surface and a bottom surface, wherein the bottom surface of the single release film comprises a first non-planar bottom surface. The first non-planar bottom surface placed over a top surface of the composite ply layup. A venting port operatively coupled directly to the top surface of the single release film. A vacuum source operatively coupled to the venting port and configured to generate a vacuum to the single release film, such that the first non-planar bottom surface of the single release film defines a breather path for the vacuum generated by the vacuum source to distribute over the top surface of the composite ply layup.Type: GrantFiled: September 19, 2014Date of Patent: June 12, 2018Assignee: The Boeing CompanyInventors: Brad Coxon, Kurtis Willden
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Publication number: 20170341357Abstract: A method of making a composite part comprises covering a mold tool for a composite part with a parting film, the parting film comprising a polymer sheet and a pressure sensitive adhesive. The parting film is positioned so that the polymer sheet is between the mold tool and the pressure sensitive adhesive. At least one layer of pre-preg is layed up on the parting film covering the mold tool to form a layed-up composite part. The pre-preg comprises an adhesive. The layed-up composite part is removed from the parting film.Type: ApplicationFiled: May 24, 2016Publication date: November 30, 2017Inventors: Hardik Dalal, Alain A. Adjorlolo, Adam F. Gross, Elena M. Sherman, John J. Vajo, Andrew P. Nowak, Brad Andrew Coxon, Kurtis Willden, Daniel M. Rotter, Stephen Lee Metschan, Berryinne Decker
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Publication number: 20160082710Abstract: System and method for compacting a composite ply layup comprising a forming tool comprising a top surface and a composite ply layup laid up along the top surface of the forming tool. A single release film comprising a top surface and a bottom surface, wherein the bottom surface of the single release film comprises a first non-planar bottom surface. The first nonplanar bottom surface placed over a top surface of the composite ply layup. A venting port operatively coupled directly to the top surface of the single release film. A vacuum source operatively coupled to the venting port and configured to generate a vacuum to the single release film, such that the first non-planar bottom surface of the single release film defines a breather path for the vacuum generated by the vacuum source to distribute over the top surface of the composite ply layup.Type: ApplicationFiled: September 19, 2014Publication date: March 24, 2016Inventors: Brad Coxon, Kurtis Willden
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Patent number: 9238335Abstract: A mandrel used to cure a composite part layup has an elastic body and at least one internal open space therein. The internal open space is configured to allow substantially uniform thermal expansion of the body during curing.Type: GrantFiled: January 8, 2009Date of Patent: January 19, 2016Assignee: THE BOEING COMPANYInventors: Brian G. Robins, Kurtis Willden, Ethan W. Hunter, Nika McManus
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Publication number: 20100009124Abstract: A mandrel used to cure a composite part layup has an elastic body and at least one internal open space therein. The internal open space is configured to allow substantially uniform thermal expansion of the body during curing.Type: ApplicationFiled: January 8, 2009Publication date: January 14, 2010Inventors: Brian G. Robins, Kurtis Willden, Ethan W. Hunter, Nika McManus
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Patent number: 7588711Abstract: A method of forming a support beam is provided. One exemplary method of forming a support beam includes supporting a C-shaped charge upon a first forming tool and placing an additional composite charge upon at least a portion of the C-shaped charge and a second forming tool proximate the first forming tool. The method of forming a support beam further includes positioning a fixed forming tool proximate a first portion of the additional charge and bending the additional charge about the forming tool.Type: GrantFiled: November 21, 2006Date of Patent: September 15, 2009Assignee: The Boeing CompanyInventors: Edoardo P. Depase, Kurtis Willden, Grant Zenkner
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Publication number: 20080115555Abstract: A method of forming a support beam is provided. One exemplary method of forming a support beam includes supporting a C-shaped charge upon a first forming tool and placing an additional composite charge upon at least a portion of the C-shaped charge and a second forming tool proximate the first forming tool. The method of forming a support beam further includes positioning a fixed forming tool proximate a first portion of the additional charge and bending the additional charge about the forming tool.Type: ApplicationFiled: November 21, 2006Publication date: May 22, 2008Inventors: Edoardo P. Depase, Kurtis Willden, Grant Zenkner
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Publication number: 20070176323Abstract: 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: ApplicationFiled: January 31, 2006Publication date: August 2, 2007Inventors: Darrell Jones, Joseph Brennan, Mark King, Kurtis Willden, George Hempstead
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Publication number: 20060291991Abstract: A machine and a method for forming composite materials are provided. The machine includes a frame and at least one forming beam attached to the frame, the at least one beam being arranged to align with a mandrel. The forming beam is pivotally segmented into at least two segments to conform to the shape of the mandrel, or alternately is bendable to conform to the shape of the mandrel. The mandrel is receivable within the frame in alignment with the forming beam. An apparatus is also provided to position a composite charge over the mandrel, and to position the mandrel within the frame. A further apparatus is provided to transport the mandrel, and to urge the mandrel toward the forming beam, forming a composite charge.Type: ApplicationFiled: August 10, 2006Publication date: December 28, 2006Applicant: THE BOEING COMPANYInventors: Kurtis Willden, Raymond Henderson, Gary Pfitzner, Surendra Parekh, Christopher Harris
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Publication number: 20060231981Abstract: A method and associated apparatus for forming a composite structural member from a charge are provided. The charge can be disposed on a first die of the apparatus and formed to a desired configuration defined by a recess of the die by inserting a second die or a tool into the recess. In some cases, the first die can include two portions that are adjustable in a transverse direction so that the recess can be opened by the insertion of the second die or tool. The second die or tool can be a substantially rigid member or an inflatable bladder. In either case, the charge can be disposed on the first die, formed, and then further processed on the first die, thereby facilitating indexing of the charge for each operation.Type: ApplicationFiled: April 13, 2005Publication date: October 19, 2006Inventors: Michael Lee, Kurtis Willden, Darrell Jones, Richard Evans