Patents by Inventor Matt Wallen

Matt Wallen 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: 10259925
    Abstract: In the manufacture of composite product, raw composite is layered on a shape or form and cured at a higher temperature. With some shapes, it is difficult or impossible to apply sufficient pressure to force and consolidate the composite material to adequately conform to the desired final shape during the curing process. The expandable tacky tape of this invention is comprised of a viscous medium incorporating thermally expandable material. Applied over the raw composite, the expandable tacky tape effectively forces the composite to conform to the desired shape during curing.
    Type: Grant
    Filed: July 28, 2015
    Date of Patent: April 16, 2019
    Inventor: Matt Wallen
  • Publication number: 20180361629
    Abstract: It is sometimes advantageous to coat or seal the mandrel before laying on, coating, or wrapping the mandrel with composite plastic material. This invention provides improved coating with improved function that is easily removable from the cured product. The effective coating materials are applied directly to the mandrel as a coat or as a film or tape. Thermally expandable coat or film also reduces manufacturing costs for composite plastic products.
    Type: Application
    Filed: August 28, 2018
    Publication date: December 20, 2018
    Inventor: Matt Wallen
  • Patent number: 10099407
    Abstract: It is sometimes advantageous to coat or seal the mandrel before laying on, coating, or wrapping the mandrel with composite plastic material. This invention provides improved coating with improved function that is easily removable from the cured product. The effective coating materials are applied directly to the mandrel as a coat or as a film or tape. Thermally expandable coat or film also reduces manufacturing costs for composite plastic products.
    Type: Grant
    Filed: May 19, 2015
    Date of Patent: October 16, 2018
    Inventor: Matt Wallen
  • Patent number: 10071506
    Abstract: A vacuum bagging system may include a layer assembly defining a fluid flow channel. The layer assembly may include a contact layer mounted to a composite part positionable within an outer mold line (OML) tool. The contact layer may have a contact layer width defined by opposing contact layer side edges. The layer assembly may further include an inner layer mounted to the contact layer and having inner layer side edges located between the contact layer side edges. The fluid flow channel may extend along at least a portion of the composite part to at least one part end. The vacuum bagging system may include an internal vacuum bag positionable against the inner layer. An inner mold line (IML) tool may support the internal vacuum bag. The contact layer width may be less than an IML tool width.
    Type: Grant
    Filed: October 29, 2015
    Date of Patent: September 11, 2018
    Assignee: The Boeing Company
    Inventors: Brett I. Lyons, Lisa C. Carlson, Stanley W. Stawski, Robert B. Miller, Matt Wallen, Jens Rossfeldt
  • Patent number: 10010829
    Abstract: The present invention is directed to methods for removing CO2 from air, which comprises exposing sorbent covered surfaces to the air. The invention also provides for an apparatus for exposing air to a CO2 sorbent. In another aspect, the invention provides a method and apparatus for separating carbon dioxide (CO2) bound in a sorbent.
    Type: Grant
    Filed: February 18, 2016
    Date of Patent: July 3, 2018
    Assignee: Carbon Sink, Inc.
    Inventors: Allen B. Wright, Klaus S. Lackner, Burton Wright, Matt Wallen, Ursula Ginster, Eddy J. Peters
  • Publication number: 20170095945
    Abstract: Although plaster (gypsum) loses water at temperatures above 300° F. and converts to plaster of Paris that has reduced structural strength, plaster (gypsum) is used in this invention as a mandrel (form or mold) at temperatures in excess of 300° F., at about 600° F. or higher in the manufacture of composite products or other products, such as metals, requiring exposure at such high temperatures. According to this invention, a plaster mandrel is effective with controlled exposure to such high temperature. Specified additive(s) to plaster, used according to this invention, greatly expand the utility of plaster containing mandrels in high temperature applications.
    Type: Application
    Filed: May 19, 2015
    Publication date: April 6, 2017
    Inventor: Matt Wallen
  • Publication number: 20170007957
    Abstract: The present invention is directed to methods for removing CO2 from air, which comprises exposing sorbent covered surfaces to the air. The invention also provides for an apparatus for exposing air to a CO2 sorbent. In another aspect, the invention provides a method and apparatus for separating carbon dioxide (CO2) hound in a sorbent.
    Type: Application
    Filed: February 18, 2016
    Publication date: January 12, 2017
    Inventors: Allen B. Wright, Klaus S. Lackner, Burton Wright, Matt Wallen, Ursula Ginster, Eddy J. Peters
  • Publication number: 20160339606
    Abstract: Although plaster (gypsum) loses water at temperatures above 300° F. and converts to plaster of Paris that has reduced structural strength, plaster (gypsum) is used in this invention as a mandrel (form or mold) at temperatures in excess of 300° F., at about 600° F. or higher in the manufacture of composite products or other products, such as metals, requiring exposure at such high temperatures. According to this invention, a plaster mandrel is effective with controlled exposure to such high temperature. Specified additive(s) to plaster, used according to this invention, greatly expand the utility of plaster containing mandrels in high temperature applications.
    Type: Application
    Filed: May 19, 2015
    Publication date: November 24, 2016
    Inventor: Matt Wallen
  • Patent number: 9498903
    Abstract: A tooling system may include an outer mold line (OML) tool and one or more inner mold line (IML) tools. The OML tool may have an OML tool surface. Each one of the IML tools may have an IML tool surface and may be receivable within the OML tool 202. Each IML tool may be formed of expandable material. Each IML tool may apply an internal compaction pressure to a composite assembly positioned between the OML tool surface and the IML tool surface when the expandable material is heated.
    Type: Grant
    Filed: October 31, 2012
    Date of Patent: November 22, 2016
    Assignee: The Boeing Company
    Inventors: Brett I. Lyons, Jens Rossfeldt, Matt Wallen, Neal A. Froeschner
  • Publication number: 20160271844
    Abstract: A tooling system may include an outer mold line (OML) tool and one or more inner mold line (IML) tools. The OML tool may have an OML tool surface. Each one of the IML tools may have an IML tool surface and may be receivable within the OML tool 202. Each IML tool may be formed of expandable material. Each IML tool may apply an internal compaction pressure to a composite assembly positioned between the OML tool surface and the IML tool surface when the expandable material is heated.
    Type: Application
    Filed: May 31, 2016
    Publication date: September 22, 2016
    Inventors: Brett I. Lyons, Jens Rossfeldt, Matt Wallen, Neal A. Froeschner
  • Publication number: 20160229090
    Abstract: A method for forming a composite structure, using a mandrel that is later removed from the composite structure, involves production of a mandrel by depositing a particulate mixture, including an aggregate and a binder, into a mold and removing the mandrel from the mold. The mandrel may be treated while still in the mold by heating, curing with an agent, microwave energy, or by some combination thereof. Once finished, the mandrel can be used in manufacturing polymer and/or composite components. The mandrel can also include materials that can be easily removed from the finished composite structure by water, shakeout, chemically dissolving, or by some combination thereof. The mandrel can be a self-expanding mandrel, and can be used in a process or system for the manufacture of composite structures.
    Type: Application
    Filed: April 18, 2016
    Publication date: August 11, 2016
    Inventors: Matt Wallen, Jens Rossfeldt, Zachary N. Wing
  • Publication number: 20160185013
    Abstract: A mandrel or core mold is used in the manufacture of composite products. The current invention avoids the disadvantages of plaster mandrels by making mandrels or core molds composed of aggregate with a dual binder system. This system produces a mold with high green strength, high dry strength, and the ability to be disintegrated from a finished composite product. The cross-linked polyvinylpyrrolidone, poly-polyvinylpyrrolidone, of this invention provides many benefits and advantages.
    Type: Application
    Filed: December 15, 2015
    Publication date: June 30, 2016
    Inventor: Matt Wallen
  • Publication number: 20160158973
    Abstract: It is sometimes advantageous to coat or seal the mandrel before laying on, coating, or wrapping the mandrel with composite plastic material. This invention provides improved coating with improved function that is easily removable from the cured product. The effective coating materials are applied directly to the mandrel as a coat or as a film or tape. Thermally expandable coat or film also reduces manufacturing costs for composite plastic products.
    Type: Application
    Filed: May 19, 2015
    Publication date: June 9, 2016
    Inventor: Matt Wallen
  • Patent number: 9314941
    Abstract: A method for forming a composite structure, using a mandrel that is later removed from the composite structure, involves production of a mandrel by depositing a particulate mixture, including an aggregate and a binder, into a mold and removing the mandrel from the mold. The mandrel may be treated while still in the mold by heating, curing with an agent, microwave energy, or by some combination thereof. Once finished, the mandrel can be used in manufacturing polymer and/or composite components. The mandrel can also include materials that can be easily removed from the finished composite structure by water, shakeout, chemically dissolving, or by some combination thereof. The mandrel can be a self-expanding mandrel, and can be used in a process or system for the manufacture of composite structures.
    Type: Grant
    Filed: May 29, 2012
    Date of Patent: April 19, 2016
    Assignee: ADVANCED CERAMICS MANUFACTURING, LLC
    Inventors: Matt Wallen, Jens Rossfeldt
  • Patent number: 9266051
    Abstract: The present invention is directed to methods for removing CO2 from air, which comprises exposing sorbent covered surfaces to the air. The invention also provides for an apparatus for exposing air to a CO2 sorbent. In another aspect, the invention provides a method and apparatus for separating carbon dioxide (CO2) bound in a sorbent.
    Type: Grant
    Filed: January 3, 2013
    Date of Patent: February 23, 2016
    Assignee: Carbon Sink, Inc.
    Inventors: Allen B. Wright, Klaus S. Lackner, Burton Wright, Matt Wallen, Ursula Ginster, Eddy J. Peters
  • Publication number: 20160046041
    Abstract: A vacuum bagging system may include a layer assembly defining a fluid flow channel. The layer assembly may include a contact layer mounted to a composite part positionable within an outer mold line (OML) tool. The contact layer may have a contact layer width defined by opposing contact layer side edges. The layer assembly may further include an inner layer mounted to the contact layer and having inner layer side edges located between the contact layer side edges. The fluid flow channel may extend along at least a portion of the composite part to at least one part end. The vacuum bagging system may include an internal vacuum bag positionable against the inner layer. An inner mold line (IML) tool may support the internal vacuum bag. The contact layer width may be less than an IML tool width.
    Type: Application
    Filed: October 29, 2015
    Publication date: February 18, 2016
    Inventors: Brett I. Lyons, Lisa C. Carlson, Stanley W. Stawski, Robert B. Miller, Matt Wallen, Jens Rossfeldt
  • Publication number: 20160032152
    Abstract: In the manufacture of composite product, raw composite is layered on a shape or form and cured at a higher temperature. With some shapes, it is difficult or impossible to apply sufficient pressure to force and consolidate the composite material to adequately conform to the desired final shape during the curing process. The expandable tacky tape of this invention is comprised of a viscous medium incorporating thermally expandable material. Applied over the raw composite, the expandable tacky tape effectively forces the composite to conform to the desired shape during curing.
    Type: Application
    Filed: July 28, 2015
    Publication date: February 4, 2016
    Inventor: Matt Wallen
  • Patent number: 9199419
    Abstract: A vacuum bagging system may include a layer assembly defining a fluid flow channel. The layer assembly may include a contact layer mounted to a composite part positionable within an outer mold line (OML) tool. The contact layer may have a contact layer width defined by opposing contact layer side edges. The layer assembly may further include an inner layer mounted to the contact layer and having inner layer side edges located between the contact layer side edges. The fluid flow channel may extend along at least a portion of the composite part to at least one part end. The vacuum bagging system may include an internal vacuum bag positionable against the inner layer. An inner mold line (IML) tool may support the internal vacuum bag. The contact layer width may be less than an IML tool width.
    Type: Grant
    Filed: October 31, 2012
    Date of Patent: December 1, 2015
    Assignee: The Boeing Company
    Inventors: Brett I. Lyons, Lisa C. Carlson, Stanley W. Stawski, Robert B. Miller, Matt Wallen, Jens Rossfeldt
  • Patent number: 8715408
    Abstract: A method for forming a composite structure, using a mandrel that is later removed from the composite structure, involves production of a mandrel by depositing a particulate mixture, including an aggregate and a binder, into a mold and removing the mandrel from the mold. The mandrel may be treated while still in the mold by heating, curing with an agent, microwave energy, or by some combination thereof. Once finished, the mandrel can be used in manufacturing polymer and/or composite components. The mandrel can also be include materials that can be easily removed from the finished composite structure by water, shakeout, chemically dissolving, or by some combination thereof.
    Type: Grant
    Filed: June 4, 2010
    Date of Patent: May 6, 2014
    Assignee: Advanced Ceramics Manufacturing, LLC
    Inventors: Matt Wallen, Jens Rossfeldt
  • Patent number: 8668856
    Abstract: A method for forming a composite structure, using a mandrel that is later removed from the composite structure, involves production of a mandrel by depositing a particulate mixture, including an aggregate and a binder, into a mold and removing the mandrel from the mold. The mandrel may be treated while still in the mold by heating, curing with an agent, microwave energy, or by some combination thereof. Once finished, the mandrel can be used in manufacturing polymer and/or composite components. The mandrel can also include materials that can be easily removed from the finished composite structure by water, shakeout, chemically dissolving, or by some combination thereof.
    Type: Grant
    Filed: August 3, 2011
    Date of Patent: March 11, 2014
    Assignee: Advanced Ceramics Mannufacturing
    Inventors: Jens Rossfeldt, Matt Wallen