Patents by Inventor Marc R. Matsen

Marc R. Matsen 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: 20090071217
    Abstract: A composite fabrication apparatus which may include a first tooling die and a second tooling die movable with respect to each other; a thermal control system having induction coils disposed in thermal contact with the first tooling die and the second tooling die; a first die susceptor provided on the first tooling die and a second die susceptor provided on the second tooling die and connected to the induction coils; and a cooling system disposed in thermal contact with the first tooling die and the second tooling die. A composite fabrication method is also disclosed.
    Type: Application
    Filed: September 13, 2007
    Publication date: March 19, 2009
    Inventors: Marc R. Matsen, Kim E. Peterson, William Dykstra
  • Publication number: 20080167833
    Abstract: Methods and systems for structural and component health monitoring are provided. A system includes a plurality of sensor systems positioned about an object to be monitored and a processing system communicatively coupled to at least one of said plurality of sensor systems wherein the processing system includes an ontology and reasoning module configured to model the object to be monitored, reason about the received sensor data associated with the object to be monitored and reason about the relationships between the received sensor data to fuse the data into contextual information for the overall object to be monitored and a contextual analyzer configured to transmit the received sensor data to said ontology and reasoning module and to store the information into a contextual information database.
    Type: Application
    Filed: January 8, 2007
    Publication date: July 10, 2008
    Inventors: Marc R. Matsen, Gary E. Georgeson, Everett Westerman, Kenneth Porad, Arun Ayyagari, Kevin Ung, Craig Farris Battles, David Blackwell
  • Publication number: 20070290803
    Abstract: A system for data synchronization of intermittently connected sensors may include an RFID system and an information management system. The system may also include an application to insure integrity of data retrieved or posted between the RFID system and the information management system.
    Type: Application
    Filed: May 30, 2007
    Publication date: December 20, 2007
    Inventors: Arun Ayyagari, Kevin Y. Ung, Marc R. Matsen, Karl L. Johnson, David B. Blackwell, William P. Coop
  • Patent number: 7269986
    Abstract: A method of forming an elongated metal blank into a structural component having a predetermined outer configuration. The method includes providing a shape imparting cavity or shell section formed from a rigid material which includes an inner surface defining the predetermined shape, placing the metal blank into the cavity or shell section, and forming the metal blank into the component by heating axial portions of the metal blank and forcing a fluid at a high pressure into the metal blank until the metal blank at least partially conforms to at least a portion of the inner surface of the cavity or shell section to form the structural component.
    Type: Grant
    Filed: January 30, 2006
    Date of Patent: September 18, 2007
    Assignee: Hot Metal Gas Forming IP 2, Inc.
    Inventors: George D. Pfaffmann, William C. Dykstra, Marc R. Matsen
  • Patent number: 7126096
    Abstract: Rib and spar webs are joined in a composite wingbox to eliminate fasteners by welding the webs along bondlines defined by overlapping sections of the webs. Heat to produce the weld is generally achieved resistively by connecting a multistrip susceptor positioned along the bond line to a current source, since the geometry makes it difficult to heat these web joints inductively. The wingbox is completed without fasteners by welding skins to the rib-spar wingbox.
    Type: Grant
    Filed: June 6, 1995
    Date of Patent: October 24, 2006
    Assignee: Th Boeing Company
    Inventors: Marc R. Matsen, Douglas A. McCarville, Michael M. Stepan
  • Patent number: 7108290
    Abstract: A device is provided for reinforcing a penetration in corrugated material having a plurality of corrugations. The device includes a tube configured to be received within the penetration. A first holder is attached to the tube, and the first holder has at least one finger arranged to engage at least one corrugation in the corrugated material. If desired, a second holder may be arranged to also engage at least one corrugation.
    Type: Grant
    Filed: June 30, 2003
    Date of Patent: September 19, 2006
    Assignee: The Boeing Company
    Inventors: David S. Nansen, Paul S. Gregg, Marc R. Matsen, John J. Gurbach, Soo Y. Oh
  • Patent number: 7109451
    Abstract: An apparatus and method for consolidating a composite workpiece are provided. The apparatus includes an electromagnetic field generator for inducing a current and thereby heating a susceptor in thermal communication with the workpiece. The workpiece is supported by one or more support tools, each of which transmits the electromagnetic field so that the support tools are not substantially heated by the electromagnetic field. Thus, the time and energy required for heating the workpiece are reduced relative to conventional consolidation techniques.
    Type: Grant
    Filed: April 29, 2005
    Date of Patent: September 19, 2006
    Assignee: The Boeing Company
    Inventors: Ronald W. Brown, Wesley B. Crow, Marc R. Matsen, Stephen G. Moore, David S. Nansen, Charles W. Newquist, Juris Verzemnieks
  • Patent number: 7102112
    Abstract: An apparatus and method for forming a composite workpiece are provided. An electromagnetic field generator induces a current in a susceptor, thereby heating the workpiece in a die cavity. An elastomeric bladder in the cavity is inflated and urges the workpiece against a contour surface corresponding to a desired configuration of the workpiece. Coolant fluid can also be circulated through the die cavity to cool the workpiece. Thus, the workpiece can be heated, formed, and cooled quickly and without substantial heating of other components, thereby reducing the time and energy relative to conventional forming methods.
    Type: Grant
    Filed: July 14, 2005
    Date of Patent: September 5, 2006
    Assignee: The Boeing Company
    Inventors: Donald A. Anderson, Ronald W. Brown, Brad L. Kirkwood, Marc R. Matsen, Douglas A. McCarville, Stephen G. Moore
  • Patent number: 7024897
    Abstract: A method of forming an elongated metal blank into a structural component having a predetermined outer configuration. The method includes providing a shape imparting cavity or shell section formed from a rigid material which includes an inner surface defining the predetermined shape, placing the metal blank into the cavity or shell section, and forming the metal blank into the component by heating axial portions of the metal blank and forcing a fluid at a high pressure into the metal blank until the metal blank at least partially conforms to at least a portion of the inner surface of the cavity or shell section to form the structural component.
    Type: Grant
    Filed: September 10, 2003
    Date of Patent: April 11, 2006
    Assignee: Hot Metal Gas Forming Intellectual Property, Inc.
    Inventors: George D. Pfaffmann, William C. Dykstra, Marc R. Matsen
  • Patent number: 6979807
    Abstract: An apparatus and method for forming a composite workpiece are provided. An electromagnetic field generator induces a current in a susceptor, thereby heating the workpiece in a die cavity. An elastomeric bladder in the cavity is inflated and urges the workpiece against a contour surface corresponding to a desired configuration of the workpiece. Coolant fluid can also be circulated through the die cavity to cool the workpiece. Thus, the workpiece can be heated, formed, and cooled quickly and without substantial heating of other components, thereby reducing the time and energy relative to conventional forming methods.
    Type: Grant
    Filed: August 13, 2003
    Date of Patent: December 27, 2005
    Assignee: The Boeing Company
    Inventors: Donald A. Anderson, Ronald W. Brown, Brad L. Kirkwood, Marc R. Matsen, Douglas A. McCarville, Stephen G. Moore
  • Patent number: 6914225
    Abstract: Apparatus and methods for single sheet forming using induction heating include a pair of dies defining a die cavity for containing a workpiece, which is inductively heated by an oscillating magnetic field within the die cavity. A susceptor is positioned between the workpiece and one die surface defined by one of the dies. The susceptor is capable of coupling with the oscillating magnetic field to induce a current within the susceptor to heat the susceptor. The susceptor transfers heat to the workpiece. An inlet for pressurized forming fluid injects the fluid between the susceptor and the workpiece to form the workpiece into direct contact with a forming surface defined by one of the dies. The susceptor may be electrically connected to the workpiece to inhibit electrical arcing from the susceptor to adjacent electrically conductive components when current is induced in the susceptor.
    Type: Grant
    Filed: June 18, 2003
    Date of Patent: July 5, 2005
    Assignee: The Boeing Company
    Inventors: John R. Fischer, Marc R. Matsen, Dwayne C. Joseph, Larry D. Hefti, Ronald W. Brown
  • Patent number: 6906300
    Abstract: An apparatus and method for consolidating a composite workpiece are provided. The apparatus includes an electromagnetic field generator for inducing a current and thereby heating a susceptor in thermal communication with the workpiece. The workpiece is supported by one or more support tools, each of which transmits the electromagnetic field so that the support tools are not substantially heated by the electromagnetic field. Thus, the time and energy required for heating the workpiece are reduced relative to conventional consolidation techniques.
    Type: Grant
    Filed: August 13, 2003
    Date of Patent: June 14, 2005
    Assignee: The Boeing Company
    Inventors: Ronald W. Brown, Marc R. Matsen, Wesley B. Crow, Stephen G. Moore, David S. Nansen, Charles W. Newquist, Juris Verzemnieks
  • Patent number: 6897419
    Abstract: A susceptor connection system and an associated apparatus and method are provided. The susceptor connection system includes at least one shoe that can be urged against a peripheral edge portion of the susceptors by a compression device. In this regard, each shoe can urge the edge portions of the susceptors together to achieve electrical contact therebetween, e.g., so that an induced current can flow between the susceptors to heat the susceptors and a workpiece. In addition, each shoe can define a passage for circulating a coolant to cool the edge portions and thereby reduce the oxidation and contact resistance between the susceptors.
    Type: Grant
    Filed: April 2, 2004
    Date of Patent: May 24, 2005
    Assignee: The Boeing Company
    Inventors: Ronald W. Brown, Larry D. Hefti, Marc R. Matsen
  • Patent number: 6884966
    Abstract: There are provided an apparatus and an associated method for manufacturing superplastically formed structural assemblies from preforms. The apparatus includes first and second co-operable dies structured to define a die cavity therebetween for at least partially receiving the preform, at least one heater in thermal communication with the die cavity for heating the preform to a forming temperature, and at least one injector in fluid communication with the die cavity. The injector is structured for injecting pressurized gas into the die cavity to urge the preform against one of the dies to form the preform into the structural assembly. Further, at least one of the injectors is structured for injecting a quenchant into the die cavity to thereby heat treat the structural assembly while distortion of the structural assembly is being at least partially restrained by at least one of the dies.
    Type: Grant
    Filed: October 22, 2002
    Date of Patent: April 26, 2005
    Assignee: The Boeing Company
    Inventors: Gary W. Coleman, John R. Fischer, Marc R. Matsen, Elizabeth M. Mull, David S. Nansen
  • Patent number: 6884976
    Abstract: An apparatus and a method for forming a localized joint in at least one structural member are provided. The apparatus includes a tool that corresponds to a joint portion of the structural member. An induction coil is disposed in the tool, and a power source is configured to energize the induction coil. A susceptor disposed between the tool and the structural member has a Curie temperature at which the susceptor becomes paramagnetic such that an electromagnetic field induced in the susceptor by the induction coil heats the susceptor to the Curie temperature for forming the joint.
    Type: Grant
    Filed: November 27, 2002
    Date of Patent: April 26, 2005
    Assignee: The Boeing Company
    Inventors: Marc R. Matsen, Terry L. Smith
  • Patent number: 6884975
    Abstract: A system and method inductively heats and stress relieves a weld joint area having a stress induced zone. A susceptor assembly is positioned over the stress induced zone. The susceptor assembly includes susceptor sheets manufactured to operate at different, preselected Curie temperatures. A housing is mounted over the susceptor assembly including an induction coil positioned adjacent to the susceptor assembly. An alternating electric current is applied to the induction coil. The alternating electric current causes the induction coil to generate a plurality of magnetic flux lines. The invention provides the advantage that the magnetic flux lines passing through the susceptor assembly heat the susceptor assembly providing localized and controlled temperature heat to the weld joint area to stress relieve the stress induced zone.
    Type: Grant
    Filed: November 12, 2002
    Date of Patent: April 26, 2005
    Assignee: The Boeing Company
    Inventors: Marc R. Matsen, Terry L. Smith
  • Patent number: 6855917
    Abstract: A die liner for use in a die having a die body wherein the die body is configured to form a workpiece. The die liner is a discrete structure that is configured to be used in conjunction with the die body. The die liner defines a forming surface for forming the workpiece and is configured to have at least one characteristic that is different than a corresponding characteristic of the die body such that the die liner increases the durability of the die.
    Type: Grant
    Filed: December 6, 2001
    Date of Patent: February 15, 2005
    Assignee: The Boeing Company
    Inventors: Marc R. Matsen, Ronald W. Brown, John R. Fischer, Brad L. Kirkwood
  • Publication number: 20040262914
    Abstract: A device is provided for reinforcing a penetration in corrugated material having a plurality of corrugations. The device includes a tube configured to be received within the penetration. A first holder is attached to the tube, and the first holder has at least one finger arranged to engage at least one corrugation in the corrugated material. If desired, a second holder may be arranged to also engage at least one corrugation.
    Type: Application
    Filed: June 30, 2003
    Publication date: December 30, 2004
    Inventors: David S. Nansen, Paul S. Gregg, Marc R. Matsen, John J. Gurbach, Soo Y. Oh
  • Publication number: 20040256383
    Abstract: Apparatus and methods for single sheet forming using induction heating include a pair of dies defining a die cavity for containing a workpiece, which is inductively heated by an oscillating magnetic field within the die cavity. A susceptor is positioned between the workpiece and one die surface defined by one of the dies. The susceptor is capable of coupling with the oscillating magnetic field to induce a current within the susceptor to heat the susceptor. The susceptor transfers heat to the workpiece. An inlet for pressurized forming fluid injects the fluid between the susceptor and the workpiece to form the workpiece into direct contact with a forming surface defined by one of the dies. The susceptor may be electrically connected to the workpiece to inhibit electrical arcing from the susceptor to adjacent electrically conductive components when current is induced in the susceptor.
    Type: Application
    Filed: June 18, 2003
    Publication date: December 23, 2004
    Inventors: John R. Fischer, Marc R. Matsen, Dwayne C. Joseph, Larry D. Hefti, Ronald W. Brown
  • Publication number: 20040200550
    Abstract: A method of forming an elongated metal blank into a structural component having a predetermined outer configuration. The method includes providing a shape imparting cavity or shell section formed from a rigid material which includes an inner surface defining the predetermined shape, placing the metal blank into the cavity or shell section, and forming the metal blank into the component by heating axial portions of the metal blank and forcing a fluid at a high pressure into the metal blank until the metal blank at least partially conforms to at least a portion of the inner surface of the cavity or shell section to form the structural component.
    Type: Application
    Filed: September 10, 2003
    Publication date: October 14, 2004
    Inventors: George D. Pfaffmann, William C. Dykstra, Marc R. Matsen