Patents by Inventor Matthew J. Kappes

Matthew J. Kappes 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: 20230193945
    Abstract: Aspects of the disclosure regard a bolt assembly which comprises a bolt extending in a longitudinal direction through a flange connection, the bolt comprising a first portion and a second portion, the first portion comprising a threaded section at a first side of the flange connection and the second portion comprising a head portion at a second side of the flange connection. The bolt assembly further comprises a nut screwed on the threaded section and a spacer arranged between the nut and the flange connection or between the head portion and the flange connection. The bolt is comprised of a titanium alloy.
    Type: Application
    Filed: April 15, 2022
    Publication date: June 22, 2023
    Inventors: Robert W. HEETER, Eric THURSTON, Jonathan M. RIVERS, Matthew J. KAPPES
  • Patent number: 11506083
    Abstract: Composite liners (such as acoustic panels, fan track liners, and/or ice impact panels or boxes for turbofan engines) and techniques for forming composite liners. In some examples, the composite liner includes at least one region comprising a reinforcement architecture comprising a matrix material, a plurality of relatively tough polymer-based reinforcement elements, and a plurality of second reinforcement elements. The plurality of relatively tough polymer-based reinforcement elements and the plurality of second reinforcement elements are embedded in the matrix material.
    Type: Grant
    Filed: June 3, 2020
    Date of Patent: November 22, 2022
    Assignee: Rolls-Royce Corporalion
    Inventors: Matthew J. Kappes, Robert Heeter, Jonathan Michael Rivers, Benedict N. Hodgson
  • Patent number: 11421538
    Abstract: A composite aerofoil may include an aerofoil body defining a leading edge and a trailing edge, wherein the body comprises a composite material including a plurality of relatively higher-modulus reinforcement elements, a plurality of relatively tougher polymer-based reinforcement elements, and a matrix material substantially encapsulating the plurality of relatively higher-modulus reinforcement elements and the plurality of relatively tougher polymer-based reinforcement elements. The plurality of relatively higher-modulus reinforcement elements are different from the plurality of relatively tougher polymer-based reinforcement elements. The disclosure also describes techniques for forming composite aerofoils.
    Type: Grant
    Filed: May 12, 2020
    Date of Patent: August 23, 2022
    Assignee: Rolls-Royce Corporation
    Inventors: Robert Heeter, Matthew J. Kappes, Jonathan Michael Rivers, Benedict N. Hodgson
  • Patent number: 11255199
    Abstract: An airfoil includes a base, a tip, a suction side face, and a pressure side face. The pressure side face includes an outer surface, an inner surface located between the outer surface and the suction side face, and a transition surface that extends between and interconnects the outer surface and the inner surface so as to form a pocket in the airfoil.
    Type: Grant
    Filed: May 20, 2020
    Date of Patent: February 22, 2022
    Assignee: Rolls-Royce Corporation
    Inventors: Dennes Kyle Burney, Jared J. Schneider, Matthew J. Kappes, Daniel Molnar, Justin McKendry, Daniel Stratton, Matthew Jordan
  • Publication number: 20210381396
    Abstract: The disclosure describes composite liners (such as acoustic panels, fan track liners, and/or ice impact panels or boxes for turbofan engines) and techniques for forming composite liners. In some examples, the composite liner includes at least one region comprising a reinforcement architecture comprising a matrix material, a plurality of relatively tough polymer-based reinforcement elements, and a plurality of second reinforcement elements. The plurality of relatively tough polymer-based reinforcement elements and the plurality of second reinforcement elements are embedded in the matrix material.
    Type: Application
    Filed: June 3, 2020
    Publication date: December 9, 2021
    Inventors: Matthew J. Kappes, Robert Heeter, Jonathan Michael Rivers, Benedict N. Hodgson
  • Patent number: 11193375
    Abstract: A fan assembly for use in a gas turbine engine of an aircraft includes a fan disk having a number of fan blades and a windage shield coupled to the fan disk to move therewith. The fan assembly supplies air for use in the engine. The windage shield rotates with the fan disk during operation of the gas turbine engine and directs air supplied by the fan blade.
    Type: Grant
    Filed: November 5, 2019
    Date of Patent: December 7, 2021
    Assignee: Rolls-Royce Corporation
    Inventors: Patrick E. Bailey, Samuel J. Lacombe, Eric W. Engebretsen, Rodney D. Conrad, Matthew J. Kappes
  • Publication number: 20210363889
    Abstract: An airfoil includes a base, a tip, a suction side face, and a pressure side face. The pressure side face includes an outer surface, an inner surface located between the outer surface and the suction side face, and a transition surface that extends between and interconnects the outer surface and the inner surface so as to form a pocket in the airfoil.
    Type: Application
    Filed: May 20, 2020
    Publication date: November 25, 2021
    Inventors: Dennes Kyle Burney, Jared J. Schneider, Matthew J. Kappes, Daniel Molnar, Justin McKendry, Daniel Stratton, Matthew Jordan
  • Publication number: 20210355833
    Abstract: A composite aerofoil may include an aerofoil body defining a leading edge and a trailing edge, wherein the body comprises a composite material including a plurality of relatively higher-modulus reinforcement elements, a plurality of relatively tougher polymer-based reinforcement elements, and a matrix material substantially encapsulating the plurality of relatively higher-modulus reinforcement elements and the plurality of relatively tougher polymer-based reinforcement elements. The plurality of relatively higher-modulus reinforcement elements are different from the plurality of relatively tougher polymer-based reinforcement elements. The disclosure also describes techniques for forming composite aerofoils.
    Type: Application
    Filed: May 12, 2020
    Publication date: November 18, 2021
    Inventors: Robert Heeter, Matthew J. Kappes, Jonathan Michael Rivers, Benedict N. Hodgson
  • Patent number: 11078839
    Abstract: The disclosure describes composite nosecones and techniques for forming composite nosecones including a matrix material, relatively higher-modulus reinforcement elements, and relatively tougher polymer-based reinforcement elements. An example composite nosecone includes a body substantially symmetrical around a central axis. The body includes a side wall defining a diameter of the body that increases from a forward side of the body to an aft side of the body. The body includes a composite material including a plurality of relatively higher-modulus reinforcement elements, a plurality of relatively tougher polymer-based reinforcement elements, and a matrix material substantially encapsulating the plurality of relatively higher-modulus reinforcement elements and the plurality of relatively tougher polymer-based reinforcement elements. The plurality of relatively higher-modulus reinforcement elements are different from the plurality of relatively tougher polymer-based reinforcement elements.
    Type: Grant
    Filed: January 22, 2018
    Date of Patent: August 3, 2021
    Assignee: Rolls-Royce Corporation
    Inventors: Robert Heeter, Matthew J. Kappes, Benedict N. Hodgson
  • Patent number: 10746031
    Abstract: An annulus filler may include an outer lid defining an airflow surface for air being drawn through the engine in an axial airflow direction and a support structure configured to connect the outer lid to a rotor disc. The annulus filler may include a composite material including a plurality of relatively high-modulus reinforcement elements, a plurality of relatively tough polymer-based reinforcement elements, and a matrix material substantially encapsulating the plurality of relatively high-modulus reinforcement elements and the plurality of relatively tough reinforcement elements.
    Type: Grant
    Filed: July 17, 2018
    Date of Patent: August 18, 2020
    Assignee: Rolls-Royce Corporation
    Inventors: Robert Heeter, Matthew J. Kappes
  • Patent number: 10731507
    Abstract: A fan case for use in a gas turbine engine of an aircraft includes an outer shroud and a liner extending along the outer shroud. The fan case provides a protective band that blocks fan blades from being thrown out of the fan case in case of a blade-off event in which a fan blade is released during operation of the gas turbine engine.
    Type: Grant
    Filed: August 28, 2015
    Date of Patent: August 4, 2020
    Assignees: Rolls-Royce Corporation, Rolls-Royce North American Technologies Inc.
    Inventors: Eric W. Engebretsen, Daniel E. Molnar, Jr., Matthew J. Kappes
  • Patent number: 10641287
    Abstract: According to one aspect, a fan containment case for a gas turbine engine is provided which includes a barrel having a first band of material on an outside of the barrel. The first band is made of carbon fiber composite. The barrel further includes a second band of material inboard of the fan case and made of poly p-phenylene-2,6-benzobisoxazole (PBO) composite. The barrel also includes a third band of material made of carbon fiber composite inboard of the second band.
    Type: Grant
    Filed: September 6, 2016
    Date of Patent: May 5, 2020
    Assignee: Rolls-Royce Corporation
    Inventors: Matthew J. Kappes, Robert W. Heeter, Benedict N. Hodgson
  • Patent number: 10634002
    Abstract: A soft wall containment system having a casing, a liner system, a containment blanket, and a barrel including multiple features is provided. The soft wall containment system may selectively be installable in a gas turbine engine having a turbine with multiple airfoils. The barrel features may be disposed outboard of the airfoils. The casing barrel may have a first thickness, the casing barrel features may have a second thickness, and the first thickness may be greater than the second thickness. Additionally, the features may be slots that extend through the thickness of the barrel.
    Type: Grant
    Filed: April 28, 2017
    Date of Patent: April 28, 2020
    Assignee: Rolls-Royce Corporation
    Inventors: Matthew A. Scott, Matthew J. Kappes
  • Publication number: 20200063563
    Abstract: A fan assembly for use in a gas turbine engine of an aircraft includes a fan disk having a number of fan blades and a windage shield coupled to the fan disk to move therewith. The fan assembly supplies air for use in the engine. The windage shield rotates with the fan disk during operation of the gas turbine engine and directs air supplied by the fan blade.
    Type: Application
    Filed: November 5, 2019
    Publication date: February 27, 2020
    Inventors: Patrick E. Bailey, Samuel J. Lacombe, Eric W. Engebretsen, Rodney D. Conrad, Matthew J. Kappes
  • Patent number: 10480321
    Abstract: A fan assembly for use in a gas turbine engine of an aircraft includes a fan disk having a number of fan blades and a windage shield coupled to the fan disk to move therewith. The fan assembly supplies air for use in the engine. The windage shield rotates with the fan disk during operation of the gas turbine engine and directs air supplied by the fan blade.
    Type: Grant
    Filed: November 18, 2015
    Date of Patent: November 19, 2019
    Assignee: Rolls-Royce Corporation
    Inventors: Patrick E. Bailey, Samuel J. Lacombe, Eric W. Engebretsen, Rodney D. Conrad, Matthew J. Kappes
  • Publication number: 20190226401
    Abstract: The disclosure describes composite nosecones and techniques for forming composite nosecones including a matrix material, relatively higher-modulus reinforcement elements, and relatively tougher polymer-based reinforcement elements. An example composite nosecone includes a body substantially symmetrical around a central axis. The body includes a side wall defining a diameter of the body that increases from a forward side of the body to an aft side of the body. The body includes a composite material including a plurality of relatively higher-modulus reinforcement elements, a plurality of relatively tougher polymer-based reinforcement elements, and a matrix material substantially encapsulating the plurality of relatively higher-modulus reinforcement elements and the plurality of relatively tougher polymer-based reinforcement elements. The plurality of relatively higher-modulus reinforcement elements are different from the plurality of relatively tougher polymer-based reinforcement elements.
    Type: Application
    Filed: January 22, 2018
    Publication date: July 25, 2019
    Inventors: Robert Heeter, Matthew J. Kappes, Benedict N. Hodgson
  • Publication number: 20190112934
    Abstract: An annulus filler may include an outer lid defining an airflow surface for air being drawn through the engine in an axial airflow direction and a support structure configured to connect the outer lid to a rotor disc. The annulus filler may include a composite material including a plurality of relatively high-modulus reinforcement elements, a plurality of relatively tough polymer-based reinforcement elements, and a matrix material substantially encapsulating the plurality of relatively high-modulus reinforcement elements and the plurality of relatively tough reinforcement elements.
    Type: Application
    Filed: July 17, 2018
    Publication date: April 18, 2019
    Inventors: Robert Heeter, Matthew J. Kappes
  • Patent number: 10247038
    Abstract: According to one aspect, a flange fastening assembly for a gas turbine engine includes a first flange having a first hole therein, a second flange having a second hole disposed adjacent to the first flange, and a shoulder bolt disposed through the first hole and the second hole. The shoulder bolt has a head portion, a stem portion, and a thread portion, and the stem portion and the thread portion define a shoulder. A bolt nut is disposed on the thread portion and a first spacer is disposed between the bolt nut and the first flange such that the first spacer overhangs the shoulder.
    Type: Grant
    Filed: October 20, 2016
    Date of Patent: April 2, 2019
    Assignee: Rolls-Royce Corporation
    Inventors: Matthew J. Kappes, Erin M. Romanowski, Dennes K. Burney
  • Publication number: 20180266271
    Abstract: A soft wall containment system having a casing, a liner system, a containment blanket, and a barrel including multiple features is provided. The soft wall containment system may selectively be installable in a gas turbine engine having a turbine with multiple airfoils. The barrel features may be disposed outboard of the airfoils. The casing barrel may have a first thickness, the casing barrel features may have a second thickness, and the first thickness may be greater than the second thickness. Additionally, the features may be slots that extend through the thickness of the barrel.
    Type: Application
    Filed: April 28, 2017
    Publication date: September 20, 2018
    Inventors: Matthew A. Scott, Matthew J. Kappes
  • Publication number: 20180112557
    Abstract: According to one aspect, a flange fastening assembly for a gas turbine engine includes a first flange having a first hole therein, a second flange having a second hole disposed adjacent to the first flange, and a shoulder bolt disposed through the first hole and the second hole. The shoulder bolt has a head portion, a stem portion, and a thread portion, and the stem portion and the thread portion define a shoulder. A bolt nut is disposed on the thread portion and a first spacer is disposed between the bolt nut and the first flange such that the first spacer overhangs the shoulder.
    Type: Application
    Filed: October 20, 2016
    Publication date: April 26, 2018
    Inventors: Matthew J. Kappes, Erin M. Romanowski, Dennes K. Burney