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).

  • Patent number: 10179940
    Abstract: A method and apparatus are present for manufacturing a part. The part is comprised of a metal alloy and is positioned to form a positioned part. An electromagnetic field is generated that heats the positioned part. A surface of the positioned part is exposed to an inert gas, while the electromagnetic field is generated to create an inverse thermal gradient between an exterior of the positioned part and an interior section of the positioned part to form a heat treated part.
    Type: Grant
    Filed: November 16, 2015
    Date of Patent: January 15, 2019
    Assignee: The Boeing Company
    Inventors: Brad L. Kirkwood, Marc R. Matsen, Tony Shen, Wesley B. Crow
  • Patent number: 10112229
    Abstract: An apparatus for forming a panel, including a first face sheet, a second face sheet and a core sheet between the first face sheet and the second face sheet, may include a molding tool defining a forming cavity shaped to correspond to the panel, a heating system positioned adjacent to the forming cavity and configured to heat the forming cavity, and a pressurization system configured to pressurize a cavity volume between the tool and the panel and pressurize a panel volume between the first face sheet and the second face sheet.
    Type: Grant
    Filed: August 17, 2015
    Date of Patent: October 30, 2018
    Assignee: The Boeing Company
    Inventors: Marc R. Matsen, David S. Nansen, Lee C. Firth, Gregory A. Foltz
  • Publication number: 20180290402
    Abstract: A fiber placement system including a fiber placement station at a first location, the fiber placement station including a tool and a fiber placement assembly configured to construct a reinforcement layup on the tool, the first fiber placement assembly including a compaction roller rotatable about an axis of rotation, the compaction roller at least partially defining a nip, a thermoplastic composite ply extending through the nip and a heating unit positioned to heat the thermoplastic composite ply proximate the nip, and a consolidation station at a consolidation location, the consolidation location being different from the first location, the consolidation station including a consolidation tool and a consolidation system configured to consolidate a reinforcement layup assembly that includes the reinforcement layup.
    Type: Application
    Filed: June 14, 2018
    Publication date: October 11, 2018
    Applicant: The Boeing Company
    Inventors: Marc R. Matsen, Mark A. Negley, Jeffery L. Marcoe, Stephen G. Moore, Brice A. Johnson, Alexandra K. Dillon, Megan M. Petersen
  • Publication number: 20180244016
    Abstract: A panel comprises a first face sheet and a second face sheet spaced apart from the first face sheet. The panel further comprises a core sheet intercoupled between the first face sheet and the second face sheet. Each of the first and second face sheets is made of a material having a thermal expansion that is different from the thermal expansion of the other face sheet.
    Type: Application
    Filed: February 27, 2017
    Publication date: August 30, 2018
    Applicant: The Boeing Company
    Inventors: Marc R. Matsen, Lee C. Firth, David S. Nansen, Michael R. Zolnowski, Carey E. Wilkinson, Gregory A. Foltz
  • Patent number: 10058950
    Abstract: An induction welding system is provided. The system includes at least one induction coil configured to generate an alternating magnetic field, and a smart susceptor film sized to be positioned between a first component and a second component to be welded to the first component. The smart susceptor film includes a thermoplastic resin, and a plurality of metal alloy wires disposed in the thermoplastic resin such that the plurality of metal alloy wires are oriented substantially parallel to the generated alternating magnetic field.
    Type: Grant
    Filed: October 25, 2012
    Date of Patent: August 28, 2018
    Assignee: The Boeing Company
    Inventors: Noel T. Gerken, Robert James Miller, Jeffery L. Marcoe, John B. Moser, Aaron W. Bartel, Marc R. Matsen
  • Publication number: 20180229463
    Abstract: A method includes a first electrode exhibiting a first Seebeck coefficient, a second electrode exhibiting a second Seebeck coefficient greater than the first Seebeck coefficient, and particles between the first and second electrodes exhibiting a third Seebeck coefficient between the first and second Seebeck coefficients. Heat is generated due to the Peltier effect at a junction between the first electrode and the particles and at a junction between the second electrode and the particles. Heat is removed due to the Peltier effect at the junction between the first electrode and the particles and at the junction between the second electrode and the particles. The particles are densified due to heating and cooling phase transitions between a higher-temperature solid phase and a lower-temperature solid phase while compressing the particles. An apparatus includes the first and second electrodes and an alternating current power supply electrically connected to the first and second electrodes.
    Type: Application
    Filed: February 13, 2017
    Publication date: August 16, 2018
    Inventors: John R. Hull, Marc R. Matsen
  • Patent number: 10016947
    Abstract: A fiber placement system including a fiber placement station at a first location, the fiber placement station including a tool and a fiber placement assembly configured to construct a reinforcement layup on the tool, the first fiber placement assembly including a compaction roller rotatable about an axis of rotation, the compaction roller at least partially defining a nip, a thermoplastic composite ply extending through the nip and a heating unit positioned to heat the thermoplastic composite ply proximate the nip, and a consolidation station at a consolidation location, the consolidation location being different from the first location, the consolidation station including a consolidation tool and a consolidation system configured to consolidate a reinforcement layup assembly that includes the reinforcement layup.
    Type: Grant
    Filed: May 21, 2015
    Date of Patent: July 10, 2018
    Assignee: The Boeing Company
    Inventors: Marc R. Matsen, Mark A. Negley, Jeffery L. Marcoe, Stephen G. Moore, Brice A. Johnson, Alexandra K. Dillon, Megan M. Petersen
  • Patent number: 10000026
    Abstract: A composite induction consolidation apparatus includes a base mandrel and a ferromagnetic base mandrel facesheet having a specific Curie temperature carried by the base mandrel. The base mandrel facesheet is adapted to support a composite part and allow ambient air pressure to compact the composite part against the base mandrel facesheet. At least one magnetic induction coil is provided in the base mandrel.
    Type: Grant
    Filed: April 8, 2011
    Date of Patent: June 19, 2018
    Assignee: The Boeing Company
    Inventors: Marc R. Matsen, Mark A Negley
  • Patent number: 9993946
    Abstract: Described herein is a method of forming tooling used to form a material. The method includes positioning a first susceptor made from a first susceptor material between first and second dies. At least one of the first and second dies includes a forming surface having a desired shape. The method further includes positioning a second susceptor made from a second susceptor material between the first and second dies such that the first susceptor is interposed between the second susceptor and the forming surface. Additionally, the method includes positioning a first bladder between the first and second dies such that the second susceptor is interposed between the first bladder and the first susceptor. Also, the method includes inflating the first bladder to concurrently deform the first susceptor and second susceptor into the desired shape.
    Type: Grant
    Filed: August 5, 2015
    Date of Patent: June 12, 2018
    Assignee: The Boeing Company
    Inventors: Marc R. Matsen, Gregory J. S. Hickman, William C. Dykstra
  • Publication number: 20180147794
    Abstract: A processing apparatus such as a heating and/or debulking apparatus that may be used to debulk a plurality of uncured composite layers to form an article such as an aircraft component may include a plurality of interconnected smart susceptor heater blankets. The plurality of smart susceptor heater blankets may be connected in series or in parallel, and may be controlled to uniformly heat the component during formation.
    Type: Application
    Filed: January 30, 2018
    Publication date: May 31, 2018
    Inventors: Andrew M. Hopkins, Donald J. Sutkus, James M. Kestner, Jennifer S. Noel, Robert J. Miller, Marc R. Matsen, Christopher J. Hottes, Mark E. King, Darren R. Walker
  • Patent number: 9930729
    Abstract: Described herein is a method of forming a heat-treated material includes positioning the heat-treated material between first and second susceptors. Each of the first and second susceptors includes a tool face shaped according to a desired shape of the heat-treated material. The method also includes applying a low-strength magnetic field to the first and second susceptors to heat the first and second susceptors. Further, the method includes compressing the heat-treated material between the first and second susceptors to form the heat-treated material into the desired shape. The method additionally includes applying a high-strength magnetic field to the heat-treated material before compressing the heat-treated material between the first and second susceptors.
    Type: Grant
    Filed: April 27, 2015
    Date of Patent: March 27, 2018
    Assignee: The Boeing Company
    Inventors: Marc R. Matsen, Mark A. Negley
  • Publication number: 20180080495
    Abstract: A shim assembly includes a shim material configured to be positioned between a first component and a second component. A wire is in contact with the shim material. The wire is configured to heat the shim material to above a predetermined temperature, and the shim material becomes moldable above the predetermined temperature such that the shim material is able to conform to the first component and the second component.
    Type: Application
    Filed: September 19, 2016
    Publication date: March 22, 2018
    Inventors: William J. Koch, Marc R. Matsen
  • Patent number: 9914269
    Abstract: A processing apparatus such as a heating and/or debulking apparatus that may be used to debulk a plurality of uncured composite layers to form an article such as an aircraft component may include a plurality of interconnected smart susceptor heater blankets. The plurality of smart susceptor heater blankets may be connected in series or in parallel, and may be controlled to uniformly heat the component during formation.
    Type: Grant
    Filed: February 29, 2016
    Date of Patent: March 13, 2018
    Assignee: THE BOEING COMPANY
    Inventors: Andrew M. Hopkins, Donald J. Sutkus, James M. Kestner, Jennifer S. Noel, Robert J. Miller, Marc R. Matsen, Christopher J. Hottes, Mark E. King, Darren R. Walker
  • Publication number: 20180065165
    Abstract: A method for forming a multilayer structure from a precursor panel having an edge, the method including steps of connecting an attachment member to the precursor panel such that an edge of the attachment member is in alignment with the edge of the precursor panel and applying heat and gas pressure to expand the precursor panel.
    Type: Application
    Filed: September 6, 2016
    Publication date: March 8, 2018
    Inventors: Marc R. Matsen, David S. Nansen, Lee C. Firth, Gregory A. Foltz
  • Publication number: 20180065314
    Abstract: A radius filler includes a plurality of fibers encapsulated in resin and braided into a braided radius filler. The braided radius filler has a substantially triangular shape with concave radius filler side surfaces and a substantially planar radius filler base surface.
    Type: Application
    Filed: October 30, 2017
    Publication date: March 8, 2018
    Inventors: Angelo Rossi, Jeffery L. Marcoe, Marc R. Matsen, Aaron W. Bartel, Waeil M. Ashmawi, Sahrudine Apdalhaliem, Adriana Willempje Blom-Schieber, David Reusch
  • Patent number: 9862175
    Abstract: A method of forming a molybdenum composite hybrid laminate is disclosed. The method includes treating a surface of each of a plurality of molybdenum foil layers. The method further includes interweaving the surface treated molybdenum foil layers with a plurality of composite material layers. The method further includes bonding with an adhesive layer each of the surface treated molybdenum foil layers to adjacent composite material layers to form a molybdenum composite hybrid laminate having improved yield strength.
    Type: Grant
    Filed: July 9, 2015
    Date of Patent: January 9, 2018
    Assignee: The Boeing Company
    Inventors: Marc R. Matsen, Mark A. Negley, Marc J. Piehl, Kay Y. Blohowiak, Alan E. Landmann, Richard H. Bossi, Robert L. Carlsen, Gregory Alan Foltz, Geoffrey A. Butler, Liam S. Cavanaugh Pingree, Stephen G. Moore, John Mark Gardner, Robert A. Anderson
  • Patent number: 9827710
    Abstract: A method of manufacturing a radius filler may include providing a plurality of fibers, braiding the plurality of fibers into a braided preform, shaping the braided preform into a braided radius filler, and cutting the braided radius filler to a desired length.
    Type: Grant
    Filed: February 4, 2014
    Date of Patent: November 28, 2017
    Assignee: The Boeing Company
    Inventors: Angelo Rossi, Jeffery L. Marcoe, Marc R. Matsen, Aaron W. Bartel
  • Publication number: 20170246817
    Abstract: A processing apparatus such as a heating and/or debulking apparatus that may be used to debulk a plurality of uncured composite layers to form an article such as an aircraft component may include a plurality of interconnected smart susceptor heater blankets. The plurality of smart susceptor heater blankets may be connected in series or in parallel, and may be controlled to uniformly heat the component during formation.
    Type: Application
    Filed: February 29, 2016
    Publication date: August 31, 2017
    Inventors: Andrew M. Hopkins, Donald J. Sutkus, James M. Kestner, Jennifer S. Noel, Robert J. Miller, Marc R. Matsen, Christopher J. Hottes, Mark E. King, Darren R. Walker
  • Publication number: 20170246815
    Abstract: A processing apparatus such as a heating and/or debulking apparatus that may be used to debulk a plurality of uncured composite layers to form an article such as an aircraft component may include a plurality of interconnected smart susceptor heater blankets. The plurality of smart susceptor heater blankets may be connected in series or in parallel, and may be controlled to uniformly heat the component during formation.
    Type: Application
    Filed: February 29, 2016
    Publication date: August 31, 2017
    Inventors: James M. Kestner, Marc R. Matsen, Scott D. Billings, John A. Mittleider, Robert J. Miller
  • Publication number: 20170165902
    Abstract: Thermoplastic welding apparatus and related methods are disclosed. An example method includes providing a smart susceptor between composite parts that are to be joined via thermoplastic welding. The example method includes positioning the composite parts and the smart susceptor on a tooling surface within a cavity of a tooling apparatus and applying a seal to the composite parts and the tooling surface to form a vacuum chamber between the composite parts and the tooling surface at a welding joint of the composite parts; producing a magnetic field at the welding joint. The example method includes providing a vacuum in the vacuum chamber during a welding operation.
    Type: Application
    Filed: January 20, 2017
    Publication date: June 15, 2017
    Inventors: Marc R. MATSEN, Mark A. NEGLEY, William Preston GEREN, Robert MILLER