Patents by Inventor Marc Campomanes
Marc Campomanes 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: 11933188Abstract: A method of manufacturing a shroud segment for gas turbine engine includes providing an insert having a plurality of pins that extend into a platform cavity portion of a mold cavity. A powder injection molding feedstock is injected. When the green part is disengaged from the mold, each elongated feature is slid out of the green part to define a respective elongated cooling passage in the platform. The method may include, after debinding and sintering, projecting a coating material while defining an obstruction between source of coating material and the open end of each elongated feature with a shoulder of the element to prevent the coating material from reaching the open end, followed by machining to remove at least a part of the shoulder.Type: GrantFiled: May 13, 2021Date of Patent: March 19, 2024Assignee: PRATT & WHITNEY CANADA CORP.Inventors: Marc Campomanes, Orlando Scalzo, Bruno Chatelois
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Patent number: 11883882Abstract: A method of forming a component from a part in the green state, including selecting at least one first portion of the part to undergo a different local volume reduction from at least one second portion to obtain the component. The green part is provided with the first portion(s) having a first solid loading and the second portion(s) having a second solid loading different from the first solid loading, then debound and sintered to obtain the component. The different first and second solid loadings produce the different local volume reduction in the first portion(s). The first portion(s) can be selected by determining a resulting final shape obtained from debinding and sintering a green part having a uniform first volumetric proportion of binder, and selecting the first portion(s) requiring a different local deformation than that producing the resulting final shape to obtain a desired final shape.Type: GrantFiled: July 21, 2021Date of Patent: January 30, 2024Assignee: PRATT & WHITNEY CANADA CORP.Inventors: Orlando Scalzo, Marc Campomanes, Guillaume Poitras
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Publication number: 20210346953Abstract: A method of forming a component from a part in the green state, including selecting at least one first portion of the part to undergo a different local volume reduction from at least one second portion to obtain the component. The green part is provided with the first portion(s) having a first solid loading and the second portion(s) having a second solid loading different from the first solid loading, then debound and sintered to obtain the component. The different first and second solid loadings produce the different local volume reduction in the first portion(s). The first portion(s) can be selected by determining a resulting final shape obtained from debinding and sintering a green part having a uniform first volumetric proportion of binder, and selecting the first portion(s) requiring a different local deformation than that producing the resulting final shape to obtain a desired final shape.Type: ApplicationFiled: July 21, 2021Publication date: November 11, 2021Inventors: Orlando SCALZO, Marc CAMPOMANES, Guillaume POITRAS
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Publication number: 20210277797Abstract: A method of manufacturing a shroud segment for gas turbine engine includes providing an insert having a plurality of pins that extend into a platform cavity portion of a mold cavity. A powder injection molding feedstock is injected. When the green part is disengaged from the mold, each elongated feature is slid out of the green part to define a respective elongated cooling passage in the platform. The method may include, after debinding and sintering, projecting a coating material while defining an obstruction between source of coating material and the open end of each elongated feature with a shoulder of the element to prevent the coating material from reaching the open end, followed by machining to remove at least a part of the shoulder.Type: ApplicationFiled: May 13, 2021Publication date: September 9, 2021Inventors: Marc CAMPOMANES, Orlando SCALZO, Bruno CHATELOIS
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Patent number: 11035249Abstract: A method of manufacturing a gas turbine engine element, for example a shroud segment. An insert has at least one elongated feature received in a mold cavity. A powder injection molding feedstock is injected. When the green part is disengaged from the mold, each elongated feature is slid out of the green part to define a respective elongated passage. The cross-sectional dimension of the elongated feature may be 0.020 inches or less, and/or a ratio between the length and cross-sectional dimension of the elongated feature may be at least 25. The method may include, after debinding and sintering, projecting a coating material while defining an obstruction between source of coating material and the open end of each elongated feature with a shoulder of the element to prevent the coating material from reaching the open end, followed by machining to remove at least a part of the shoulder.Type: GrantFiled: July 23, 2014Date of Patent: June 15, 2021Assignee: PRATT & WHITNEY CANADA CORP.Inventors: Marc Campomanes, Orlando Scalzo, Bruno Chatelois
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Patent number: 10226818Abstract: A process for joining two or more powder injection molded parts by preparing at least two green parts from a feedstock including a binder and an injection powder. Placing the two or more green part into intimate contact, and maintaining the two green parts in intimate contact at a position with a linkage between the at least two green parts to produce an interconnected green assembly. Placing the assembly under shape retaining conditions, melting the binder of the interconnected green assembly under shape retaining conditions to produce a seamless body.Type: GrantFiled: March 20, 2009Date of Patent: March 12, 2019Assignee: PRATT & WHITNEY CANADA CORP.Inventors: Orlando Scalzo, Marc Campomanes, Melissa Despres, Alain Bouthillier, Vincent Savaria
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Patent number: 10011044Abstract: A method of manufacturing a part, including providing a green body made of powder injection molding material and connected to a solid support member partially contained in the green body. The support member is engaged with a retaining fixture of a machine tool. While supporting the green body through the engagement between the support member and the retaining fixture, the green body is machined to obtain a machined green part. The machined green part is debound and sintered. A method of forming a powder injection molding part in a green state including machining a molded body using a machine tool while supporting the blank with a retaining fixture, and a machining blank having a green body and a solid support member including one locating feature of a pair of complementary locating features snuggly engageable with one another are also discussed.Type: GrantFiled: September 8, 2014Date of Patent: July 3, 2018Assignee: PRATT & WHITNEY CANADA CORP.Inventors: Marc Campomanes, Orlando Scalzo, Jean Fournier, Guillaume Poitras
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Publication number: 20180149087Abstract: A cooled wall segment for a gas turbine engine, including a body defining a contact surface configured to be in contact with circulating hot gas and an outer surface configured to be in contact with cooling air, the body including at least one retention element complementary to a retention element of the engine. The body has a first portion including the at least one retention element, and a porous second portion made of a porous material permeable to air and containing a plurality of interconnected pores, the porous material having a porosity greater than that of the first portion, the second portion being engaged to the first portion and defining at least part of the contact surface, the second portion defining at least part of a fluid communication between the outer surface and the contact surface through the interconnected pores. Methods of forming components are also discussed.Type: ApplicationFiled: January 26, 2018Publication date: May 31, 2018Inventors: Marc CAMPOMANES, Orlando SCALZO, Alain BOUTHILLIER
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Patent number: 9970318Abstract: A method of manufacturing a shroud segment, including separately molding at least first and second parts by powder injection molding. The first part has an inner surface and at least one fluid passage in communication with the inner surface. The second part has an outer surface complementary to the inner surface of the first part. At least one of the inner and outer surfaces is formed to define a plurality of grooves. A plurality of cooling passages in fluid communication with the at least one fluid passage are defined with the plurality of grooves by interconnecting the inner and outer surfaces while the first and second parts remain in a green state. The interconnected parts are debound and sintered to fuse the parts to define at least a portion of the shroud segment including the cooling passages.Type: GrantFiled: June 25, 2014Date of Patent: May 15, 2018Assignee: PRATT & WHITNEY CANADA CORP.Inventors: Orlando Scalzo, Marc Campomanes, Eric Hosking, Alain Bouthillier
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Patent number: 9903275Abstract: A component including a porous portion which may be permeable or impermeable to air, and a method for making. In one example, the component is a cooled wall segment for a gas turbine engine, including a body defining a contact surface configured to be in contact with circulating hot gas and an outer surface configured to be in contact with cooling air. The body includes a first portion with at least one retention element, and a porous second portion made of a porous material permeable to air, containing a plurality of interconnected pores, and having a porosity greater than that of the first portion. The second portion is engaged to the first portion, defines at least part of the contact surface, and defines at least part of a fluid communication between the outer surface and the contact surface through the interconnected pores. The wall segment may be for example a heat shield or shroud segment. Methods of forming components are also discussed.Type: GrantFiled: February 27, 2014Date of Patent: February 27, 2018Assignee: PRATT & WHITNEY CANADA CORP.Inventors: Marc Campomanes, Orlando Scalzo, Alain Bouthillier
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Patent number: 9862028Abstract: A method of supporting a part with particulate shape retaining media, the method including placing the part on a bed of the particulate shape retaining media, fluidizing the particulate shape retaining media until the part penetrates therein, and vibrating the bed of particulate shape retaining media to compact the particulate shape retaining media around the part. The part may be a green part to be debound in a powder injection molding process. Fluidization may be performed through vibrations at a different frequency than the compaction.Type: GrantFiled: December 22, 2016Date of Patent: January 9, 2018Assignee: PRATT & WHITNEY CANADA CORP.Inventors: Orlando Scalzo, Marc Campomanes
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Patent number: 9731349Abstract: A mold assembly includes a first mold part having guide passages defined therein. Protruding members are each movably received in a first portion of a respective guide passage to extend selectively in and out of the mold cavity. At least some of the protruding members are movable along different directions from one another. Cables are each connected to one of the protruding members and extend through a linear second portion of the respective guide passage and out of the first mold part. An actuator is connected to the cables and movable relative to the first mold part between an extended position and a retracted position. In the extended position, each protruding member protrudes into the mold cavity. In the retracted position, each of protruding member is retracted out of the mold cavity and contained within the respective guide passage. A guide element and a method of molding are also discussed.Type: GrantFiled: April 10, 2015Date of Patent: August 15, 2017Assignee: PRATT & WHITNEY CANADA CORP.Inventors: Marc Campomanes, Orlando Scalzo
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Patent number: 9700986Abstract: A method of machining a turbine shroud segment including inserting an annular flange of a grinding wheel through a first gap defined between the shroud retention elements and into a second gap defined between the shroud platform and an axially extending, radially inwardly facing arcuate inner surface of one of the retention elements. The wheel flange is inserted with its supporting leg and the wheel body remaining out of contact with the shroud segment and with the wheel flange remaining out of contact with the platform. The inner surface is ground through contact with an annular outer grinding surface of the wheel flange. The wheel leg and body remain out of contact with the shroud segment and the wheel flange remains out of contact with the platform during grinding.Type: GrantFiled: May 6, 2014Date of Patent: July 11, 2017Assignee: PRATT & WHITNEY CANADA CORP.Inventor: Marc Campomanes
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Publication number: 20170100774Abstract: A method of supporting a part with particulate shape retaining media, the method including placing the part on a bed of the particulate shape retaining media, fluidizing the particulate shape retaining media until the part penetrates therein, and vibrating the bed of particulate shape retaining media to compact the particulate shape retaining media around the part. The part may be a green part to be debound in a powder injection molding process. Fluidization may be performed through vibrations at a different frequency than the compaction.Type: ApplicationFiled: December 22, 2016Publication date: April 13, 2017Inventors: Orlando SCALZO, Marc CAMPOMANES
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Patent number: 9550235Abstract: A method of supporting a part with particulate shape retaining media, the method including placing the part on a bed of the particulate shape retaining media, fluidizing the particulate shape retaining media until the part penetrates therein, and vibrating the bed of particulate shape retaining media to compact the particulate shape retaining media around the part. The part may be a green part to be debound in a powder injection molding process. Fluidization may be performed through vibrations at a different frequency than the compaction.Type: GrantFiled: August 7, 2013Date of Patent: January 24, 2017Assignee: PRATT & WHITNEY CANADA CORPInventors: Orlando Scalzo, Marc Campomanes
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Patent number: 9517507Abstract: A method of shaping a part in a green state obtained through powder injection molding, including placing a surface of the part in contact with a shaping surface of a setter with at least one section of the surface of the part not conforming to the shaping surface, and locally heating at least one area of each of the at least one section to deform the part until the at least one section conforms to the shaping surface. The part remains in the green state during the local heating. The part may be a heat shield panel for a gas turbine engine.Type: GrantFiled: July 17, 2014Date of Patent: December 13, 2016Assignee: PRATT & WHITNEY CANADA CORP.Inventors: Marc Campomanes, Orlando Scalzo, Guillaume Poitras
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Publication number: 20160279698Abstract: A mold assembly includes a first mold part having guide passages defined therein. Protruding members are each movably received in a first portion of a respective guide passage to extend selectively in and out of the mold cavity. At least some of the protruding members are movable along different directions from one another. Cables are each connected to one of the protruding members and extend through a linear second portion of the respective guide passage and out of the first mold part. An actuator is connected to the cables and movable relative to the first mold part between an extended position and a retracted position. In the extended position, each protruding member protrudes into the mold cavity. In the retracted position, each of protruding member is retracted out of the mold cavity and contained within the respective guide passage. A guide element and a method of molding are also discussed.Type: ApplicationFiled: April 10, 2015Publication date: September 29, 2016Inventors: Marc CAMPOMANES, Orlando SCALZO
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Publication number: 20160263656Abstract: A method of forming a component from a part in the green state, including selecting at least one first portion of the part to undergo a different local volume reduction from at least one second portion to obtain the component. The green part is provided with the first portion(s) having a first solid loading and the second portion(s) having a second solid loading different from the first solid loading, then debound and sintered to obtain the component. The different first and second solid loadings produce the different local volume reduction in the first portion(s). The first portion(s) can be selected by determining a resulting final shape obtained from debinding and sintering a green part having a uniform first volumetric proportion of binder, and selecting the first portion(s) requiring a different local deformation than that producing the resulting final shape to obtain a desired final shape.Type: ApplicationFiled: March 12, 2015Publication date: September 15, 2016Inventors: Orlando SCALZO, Marc CAMPOMANES, Guillaume POITRAS
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Publication number: 20160024966Abstract: A method of manufacturing a gas turbine engine element, for example a shroud segment. An insert has at least one elongated feature received in a mold cavity. A powder injection molding feedstock is injected. When the green part is disengaged from the mold, each elongated feature is slid out of the green part to define a respective elongated passage. The cross-sectional dimension of the elongated feature may be 0.020 inches or less, and/or a ratio between the length and cross-sectional dimension of the elongated feature may be at least 25. The method may include, after debinding and sintering, projecting a coating material while defining an obstruction between source of coating material and the open end of each elongated feature with a shoulder of the element to prevent the coating material from reaching the open end, followed by machining to remove at least a part of the shoulder.Type: ApplicationFiled: July 23, 2014Publication date: January 28, 2016Inventors: Marc CAMPOMANES, Orlando SCALZO, Bruno CHATELOIS
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Publication number: 20160016230Abstract: A method of shaping a part in a green state obtained through powder injection molding, including placing a surface of the part in contact with a shaping surface of a setter with at least one section of the surface of the part not conforming to the shaping surface, and locally heating at least one area of each of the at least one section to deform the part until the at least one section conforms to the shaping surface. The part remains in the green state during the local heating. The part may be a heat shield panel for a gas turbine engine.Type: ApplicationFiled: July 17, 2014Publication date: January 21, 2016Inventors: Marc CAMPOMANES, Orlando SCALZO, Guillaume POITRAS