Patents by Inventor Matthew H. Cawthorne
Matthew H. Cawthorne 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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Publication number: 20240091891Abstract: A method for repairing a crack in a structure includes mounting a manifold to the structure around the crack. The structure has a nonplanar surface contour that surrounds the crack. The manifold has a base portion, a cover portion, and a plug. The base portion has a grip surface configured to conform to the nonplanar surface contour of the structure. The cover portion is connected to the base portion, and has an injection port and a vent port in fluid communication with a channel aligned to the crack. The injection port transfers a bonding material into and out of the channel. The plug closes and opens the vent port. The method includes filling the channel with the bonding material to direct the bonding material into the crack, and draining the bonding material from the manifold.Type: ApplicationFiled: November 28, 2023Publication date: March 21, 2024Applicant: The Boeing CompanyInventors: Michael J. Deluca, Matthew H. Cawthorne, Howard T. Rolleston
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Patent number: 11865656Abstract: A method for repairing a crack in a structure includes mounting a manifold to the structure around the crack. The structure has a nonplanar surface contour that surrounds the crack. The manifold has a base portion, a cover portion, and a plug. The base portion has a grip surface configured to conform to the nonplanar surface contour of the structure. The cover portion is connected to the base portion, and has an injection port and a vent port in fluid communication with a channel aligned to the crack. The injection port transfers a bonding material into and out of the channel. The plug closes and opens the vent port. The method includes filling the channel with the bonding material to direct the bonding material into the crack, and draining the bonding material from the manifold.Type: GrantFiled: February 22, 2022Date of Patent: January 9, 2024Assignee: The Boeing CompanyInventors: Michael J. Deluca, Matthew H. Cawthorne, Howard T. Rolleston
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Publication number: 20220402081Abstract: A method for repairing a crack in a structure includes mounting a manifold to the structure around the crack. The structure has a nonplanar surface contour that surrounds the crack. The manifold has a base portion, a cover portion, and a plug. The base portion has a grip surface configured to conform to the nonplanar surface contour of the structure. The cover portion is connected to the base portion, and has an injection port and a vent port in fluid communication with a channel aligned to the crack. The injection port transfers a bonding material into and out of the channel. The plug closes and opens the vent port. The method includes filling the channel with the bonding material to direct the bonding material into the crack, and draining the bonding material from the manifold.Type: ApplicationFiled: February 22, 2022Publication date: December 22, 2022Applicant: The Boeing CompanyInventors: Michael J. Deluca, Matthew H. Cawthorne, Howard T. Rolleston
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Patent number: 11167864Abstract: Systems and methods are provided for applying cold spray erosion protection to an airfoil. One embodiment is a method for applying an abrasion coating to a fiber-reinforced composite substrate. The method includes applying a bond layer to the fiber-reinforced composite substrate by emitting, with a supersonic nozzle of a High Pressure Cold Spray (HPCS) system, a first gas stream including a first metal powder at a first speed below supersonic speed. The method further includes applying a cold spray deposit layer to the bond layer by emitting, with the supersonic nozzle, a second gas stream including a second metal powder at a second speed above supersonic speed.Type: GrantFiled: April 27, 2018Date of Patent: November 9, 2021Assignee: The Boeing CompanyInventors: Matthew H. Cawthorne, Bruno Zamorano Senderos, Kenneth W. Young
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Patent number: 11135829Abstract: A system for forming a structural member which includes a first collimated light source and a reservoir containing a volume of photo-monomer resin wherein the first collimated light source is positioned spaced apart from the photo-monomer resin. The system further includes a first face sheet structure defining at least one bore which extends through the first face sheet structure wherein a portion of the first face sheet structure is positioned under a surface of the volume of photo-monomer resin such that photo-monomer resin is positioned within the bore.Type: GrantFiled: September 30, 2016Date of Patent: October 5, 2021Assignee: THE BOEING COMPANYInventors: Sophia Yang, Matthew H. Cawthorne, Edward W. Brouwers, Jacob Michael Hundley, Zak Charles Eckel, Scott Biesboer, Kenneth Cante
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Publication number: 20190329906Abstract: Systems and methods are provided for applying cold spray erosion protection to an airfoil. One embodiment is a method for applying an abrasion coating to a fiber-reinforced composite substrate. The method includes applying a bond layer to the fiber-reinforced composite substrate by emitting, with a supersonic nozzle of a High Pressure Cold Spray (HPCS) system, a first gas stream including a first metal powder at a first speed below supersonic speed. The method further includes applying a cold spray deposit layer to the bond layer by emitting, with the supersonic nozzle, a second gas stream including a second metal powder at a second speed above supersonic speed.Type: ApplicationFiled: April 27, 2018Publication date: October 31, 2019Inventors: Matthew H. Cawthorne, Bruno Zamorano Senderos, Kenneth W. Young
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Patent number: 9957917Abstract: A nozzle including a frame having a plurality of deflecting elements arranged in an array, the array extending about a longitudinal axis, and a skin positioned over the frame.Type: GrantFiled: August 8, 2014Date of Patent: May 1, 2018Assignee: The Boeing CompanyInventors: Matthew H. Cawthorne, Evan J. Filter
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Publication number: 20180093428Abstract: A system for forming a structural member which includes a first collimated light source and a reservoir containing a volume of photo-monomer resin wherein the first collimated light source is positioned spaced apart from the photo-monomer resin. The system further includes a first face sheet structure defining at least one bore which extends through the first face sheet structure wherein a portion of the first face sheet structure is positioned under a surface of the volume of photo-monomer resin such that photo-monomer resin is positioned within the bore.Type: ApplicationFiled: September 30, 2016Publication date: April 5, 2018Inventors: Sophia Yang, Matthew H. Cawthorne, Edward W. Brouwers, Jacob Michael Hundley, Zak Charles Eckel, Scott Biesboer, Kenneth Cante
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Publication number: 20170087745Abstract: A method for making a thermoplastic composite structure includes the steps of: (1) placing, in situ, fiber-reinforced thermoplastic material around a mandrel, wherein the mandrel includes a soluble material, (2) consolidating, in situ, the fiber-reinforced thermoplastic material to form a thermoplastic composite structure, and (3) at least partially solubilizing the mandrel from within the thermoplastic composite structure to remove the mandrel and provide the thermoplastic composite structure including a material thickness of the fiber-reinforced thermoplastic material, a structure shape, and a hollow interior.Type: ApplicationFiled: September 30, 2015Publication date: March 30, 2017Inventor: Matthew H. Cawthorne
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Patent number: 9440737Abstract: Apparatus to adjust airfoils of rotor blades are disclosed. An example apparatus includes a first surface to be attached to a trailing edge of a rotor blade; a forward edge having a first thickness; an aft edge having a second thickness; and a middle portion between the forward edge and the aft edge having a third thickness greater than the first and second thicknesses.Type: GrantFiled: May 11, 2012Date of Patent: September 13, 2016Assignee: THE BOEING COMPANYInventors: Matthew H. Cawthorne, Robert P. Narducci, Perry Ray Ziegenbein
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Publication number: 20160040625Abstract: A nozzle including a frame having a plurality of deflecting elements arranged in an array, the array extending about a longitudinal axis, and a skin positioned over the frame.Type: ApplicationFiled: August 8, 2014Publication date: February 11, 2016Inventors: Matthew H. Cawthorne, Evan J. Filter
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Patent number: 8029240Abstract: In one embodiment, a rotor blade balancing apparatus may include a tube member defining an inner cavity, a plurality of weights, and a biasing member. The tube member may be for the insertion into a cavity of a rotor blade. Each of the weights may be adapted to be slide-ably inserted into the inner cavity of the tube member within a cavity of a rotor blade, and slide-ably removed from the inner cavity of the tube member within a cavity of a rotor blade in order to balance a rotor blade. The biasing member may be for biasing weights, which have been slide-ably inserted into the inner cavity of the tube member within a cavity of a rotor blade, towards an end of the tube member.Type: GrantFiled: November 8, 2007Date of Patent: October 4, 2011Assignee: The Boeing CompanyInventors: Matthew H. Cawthorne, Steven J. Spear, Christopher J. Cline
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Publication number: 20110002785Abstract: In one embodiment, a rotor blade balancing apparatus may include a tube member defining an inner cavity, a plurality of weights, and a biasing member. The tube member may be for the insertion into a cavity of a rotor blade. Each of the weights may be adapted to be slide-ably inserted into the inner cavity of the tube member within a cavity of a rotor blade, and slide-ably removed from the inner cavity of the tube member within a cavity of a rotor blade in order to balance a rotor blade. The biasing member may be for biasing weights, which have been slide-ably inserted into the inner cavity of the tube member within a cavity of a rotor blade, towards an end of the tube member.Type: ApplicationFiled: November 8, 2007Publication date: January 6, 2011Applicant: THE BOEING COMPANYInventors: MATTHEW H. CAWTHORNE, STEVEN J. SPEAR, CHRISTOPHER J. CLINE
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Patent number: 7509873Abstract: A coupon fabrication with defined distortion in the form of marceled fibers and test protocol is employed to determine the shape of the failure probability density curve to improve the analyses of the risk of fiber distortion anomalies in composite structures. This protocol provides a method to determine the probability of and the severity of the various distorted fiber conditions that might exist on composite structure in fabrication and in service. A distortion characterization matrix is established for determining test shapes and providing defect characterization based on the results of tests on the selected shapes. Coupons for test are created using resin pool.Type: GrantFiled: December 22, 2006Date of Patent: March 31, 2009Assignee: The Boeing CompanyInventors: Sharyn E. Mlinar, Matthew H. Cawthorne, David L. Downey, Donna M. Irby
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Publication number: 20080148865Abstract: A coupon fabrication with defined distortion in the form of marceled fibers and test protocol is employed to determine the shape of the failure probability density curve to improve the analyses of the risk of fiber distortion anomalies in composite structures. This protocol provides a method to determine the probability of and the severity of the various distorted fiber conditions that might exist on composite structure in fabrication and in service. A distortion characterization matrix is established for determining test shapes and providing defect characterization based on the results of tests on the selected shapes.Type: ApplicationFiled: December 22, 2006Publication date: June 26, 2008Applicant: THE BOEING COMPANYInventors: Sharyn E. Mlinar, Matthew H. Cawthorne, David L. Downey, Donna M. Irby