Patents by Inventor Michael G. McCaffrey

Michael G. McCaffrey 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: 11976568
    Abstract: Disclosed is a ceramic matrix component having a fibrous core and a ceramic matrix composite shell surrounding at least a portion of the fibrous core. The ceramic matrix composite shell comprises a fibrous preform. The fibrous core has a greater porosity than the fibrous preform. A method of making the ceramic matrix component is also disclosed.
    Type: Grant
    Filed: April 10, 2023
    Date of Patent: May 7, 2024
    Assignee: RTX CORPORATION
    Inventors: Michael G. McCaffrey, Bryan P. Dube
  • Publication number: 20240102400
    Abstract: A method includes providing a ceramic insert on a mandrel, the mandrel and the ceramic insert together define a peripheral working surface, forming a fiber preform by wrapping a fiber layer around the mandrel and the ceramic insert so as to conform to the peripheral working surface, removing the mandrel from the fiber preform to leave a cavity in the fiber preform, the ceramic insert remaining in the fiber preform and bordering the cavity, and densifying the fiber preform with a ceramic matrix to form a gas turbine engine component.
    Type: Application
    Filed: December 4, 2023
    Publication date: March 28, 2024
    Inventor: Michael G. McCaffrey
  • Publication number: 20240043350
    Abstract: A method of forming a feature on an article includes applying a powder material stock to a surface of an article, the powder material stock being capable of being transformed into a solid feature by the application of energy; applying energy to a portion of the powder material stock within a footprint of a feature to form the feature within the footprint; and removing excess powder material stock from the surface of the article. A coated article is also disclosed.
    Type: Application
    Filed: August 7, 2023
    Publication date: February 8, 2024
    Inventor: Michael G. McCaffrey
  • Patent number: 11873589
    Abstract: Disclosed is a weaving assembly including a rotatable base, a base positional controller, a weave control grid, a warp fiber support, warp fiber arms, a warp fiber arm positional controller and a fill fiber wand.
    Type: Grant
    Filed: December 19, 2022
    Date of Patent: January 16, 2024
    Assignee: RTX CORPORATION
    Inventor: Michael G. McCaffrey
  • Patent number: 11867067
    Abstract: An article includes a gas turbine engine component that has a ceramic matrix composite (CMC) body and a fiber layer circumscribing a cavity. There is a ceramic insert incorporated into the CMC article body, the insert bordering the cavity.
    Type: Grant
    Filed: June 3, 2022
    Date of Patent: January 9, 2024
    Assignee: RTX CORPORATION
    Inventor: Michael G. McCaffrey
  • Patent number: 11852345
    Abstract: A hot fairing structure for a pre-diffuser includes a ring-strut-ring structure that comprises a multiple of hollow struts and a multiple of inlets to a respective diffusion passage, one of the multiple of inlets formed between each one of the multiple of hollow struts located between two diffusion passages.
    Type: Grant
    Filed: June 22, 2022
    Date of Patent: December 26, 2023
    Assignee: RTX Corporation
    Inventors: Michael G. McCaffrey, Matthew Andrew Hough, Pedro E. Rivero
  • Patent number: 11852019
    Abstract: Disclosed herein is a seal comprising an annular ring comprising: an outer diameter surface having an outer diameter, an inner diameter surface, a first height measured from the outer diameter surface to the inner diameter surface, wherein a first ratio of the outer diameter to the first height is greater than 10:1; and a cross-sectional shape comprising: a central beam extending from an inner end to an outer end, the central beam including a central axis that defines an angle with a neutral axis of the cross-sectional shape, the angle being between 5 degrees and 25 degrees; a first flange extending axially from the inner end of the central beam in a first axial direction; and a second flange extending axially from the outer end of the central beam in a second axial direction, the second axial direction being opposite the first axial direction.
    Type: Grant
    Filed: June 7, 2023
    Date of Patent: December 26, 2023
    Assignee: RTX CORPORATION
    Inventor: Michael G. McCaffrey
  • Patent number: 11846204
    Abstract: A ceramic matrix composite blade includes a central core surrounded by an outer profile, the central core comprising layers of unidirectional layup having two dimension and three dimension fiber weaves; the outer profile comprises a biased weave layup that radiates toward a leading edge and a trailing edge of the blade; wherein the biased weave layup includes fibers that extend proximate an attachment region of the blade radially and axially along an airfoil portion of the blade toward the leading edge and trailing edge.
    Type: Grant
    Filed: March 18, 2022
    Date of Patent: December 19, 2023
    Assignee: RTX Corporation
    Inventor: Michael G. McCaffrey
  • Publication number: 20230392511
    Abstract: An article includes a gas turbine engine component that has a ceramic matrix composite (CMC) body and a fiber layer circumscribing a cavity. There is a ceramic insert incorporated into the CMC article body, the insert bordering the cavity.
    Type: Application
    Filed: June 3, 2022
    Publication date: December 7, 2023
    Inventor: Michael G. McCaffrey
  • Publication number: 20230392506
    Abstract: A vane arc segment includes ceramic matrix composite (CMC) fairing that has an airfoil section, a first single-sided platform at the outer radial end projecting from the suction side wall, and a second single-sided platform at the inner radial end projecting from the pressure side wall. The first single-sided platform is comprised of a fiber layer that extends from the airfoil section and turns into the first single-sided platform, and the second single-sided platform is comprised of the fiber layer that from the airfoil section and turns into the second single-sided platform.
    Type: Application
    Filed: June 3, 2022
    Publication date: December 7, 2023
    Inventor: Michael G. McCaffrey
  • Patent number: 11834762
    Abstract: Disclosed is a weaving method including placing a first section of a fill fiber between warp fibers, forming a pick, moving a base to reposition the warp fibers, and placing a second section of the fill fiber between the warp fibers to form a woven structure, wherein at least a portion of the warp fibers are introduced to the woven structure using a weave control grid. Also disclosed is a weaving assembly including a base, a base positional controller, a weave control grid, warp fiber arms, a warp fiber arm positional controller and a fill fiber wand.
    Type: Grant
    Filed: November 7, 2022
    Date of Patent: December 5, 2023
    Assignee: RTX CORPORATION
    Inventor: Michael G. McCaffrey
  • Publication number: 20230383695
    Abstract: A propulsion system includes a first propulsor rotor, a second propulsor rotor and a gas turbine engine core. The first propulsor rotor is configured to generate propulsive thrust. The second propulsor rotor is configured to generate propulsive lift. The gas turbine engine core includes a compressor section, a combustor section, a turbine section and a rotating structure. The rotating structure includes a turbine rotor within the turbine section. The gas turbine engine core is configured to rotate the rotating structure at a first rotational speed during a first mode to drive the first propulsor rotor to generate the propulsive thrust. The gas turbine engine core is configured to rotate the rotating structure at a second rotational speed during a second mode to drive the second propulsor rotor to generate the propulsive lift. The second rotational speed may be less than eighty percent of the first rotational speed.
    Type: Application
    Filed: May 26, 2023
    Publication date: November 30, 2023
    Inventors: Paul R. Hanrahan, Michael G. McCaffrey
  • Patent number: 11808154
    Abstract: In one exemplary embodiment, a flow path component assembly includes a support structure having an axial portion and a radial portion and an outer portion arranged between the support structure. The outer portion defines a gap between the outer portion and the axial portion of the support structure. A flange is positioned relative to the gap.
    Type: Grant
    Filed: September 26, 2022
    Date of Patent: November 7, 2023
    Assignee: RTX CORPORATION
    Inventors: San Quach, Bryan P. Dube, Erik R. Granstand, Michael G. McCaffrey, Stephen G. Pixton
  • Patent number: 11773723
    Abstract: An airfoil includes an airfoil section that has a ceramic airfoil wall that defines a suction side and a pressure side. There is an interior cavity in the airfoil section. A rib spans across the interior cavity and connects the suction side and the pressure side. The rib has a thermal conductance element that is configured to conduct heat away from the suction side and the pressure side.
    Type: Grant
    Filed: November 15, 2019
    Date of Patent: October 3, 2023
    Assignee: RTX CORPORATION
    Inventors: Bryan P. Dube, Michael G. McCaffrey
  • Publication number: 20230296026
    Abstract: A ceramic matrix composite blade includes a central core surrounded by an outer profile, the central core comprising layers of unidirectional layup having two dimension and three dimension fiber weaves; the outer profile comprises a biased weave layup that radiates toward a leading edge and a trailing edge of the blade; wherein the biased weave layup includes fibers that extend proximate an attachment region of the blade radially and axially along an airfoil portion of the blade toward the leading edge and trailing edge.
    Type: Application
    Filed: March 18, 2022
    Publication date: September 21, 2023
    Applicant: Raytheon Technologies Corporation
    Inventor: Michael G. McCaffrey
  • Publication number: 20230296028
    Abstract: A method of damping vibrations in a seal includes inserting a first wave spring between a first beam and a second beam of the seal. The seal can be for a gas turbine engine and can include a full hoop outer ring, a shoe coupled to the full hoop outer ring via the first beam (e.g., an outer beam) and the second beam (e.g., an inner beam), and the first wave spring in contact with the first beam and the second beam.
    Type: Application
    Filed: May 3, 2023
    Publication date: September 21, 2023
    Applicant: RAYTHEON TECHNOLOGIES CORPORATION
    Inventors: Ross Wilson, John R. Farris, Michael G. McCaffrey, Theodore W. Hall, John J. Korzendorfer, Elizabeth F. Vinson, Jeffrey Michael Jacques, John E. Paul, Edwin Otero, Alan W. Stoner
  • Publication number: 20230250726
    Abstract: Disclosed is a ceramic matrix component having a fibrous core and a ceramic matrix composite shell surrounding at least a portion of the fibrous core. The ceramic matrix composite shell comprises a fibrous preform. The fibrous core has a greater porosity than the fibrous preform. A method of making the ceramic matrix component is also disclosed.
    Type: Application
    Filed: April 10, 2023
    Publication date: August 10, 2023
    Inventors: Michael G. McCaffrey, Bryan P. Dube
  • Publication number: 20230250728
    Abstract: A turbine for a gas turbine engine includes, among other things, a shaft rotatable about a longitudinal axis, a turbine rotor including one or more rows of turbine blades and a disk assembly coupled to the shaft. The disk assembly includes one or more disks each having an attachment region extending radially between an inner boundary and an outer boundary, the outer boundary is established by an outer periphery of the respective disk, the attachment region defines an array of slots distributed about the outer periphery, each of the slots extends radially inwardly from the outer boundary to the inner boundary, and each of the slots is dimensioned to receive a root section of a respective one of the turbine blades to mount the turbine blades to the disk assembly.
    Type: Application
    Filed: March 20, 2023
    Publication date: August 10, 2023
    Inventor: Michael G. McCaffrey
  • Patent number: 11702950
    Abstract: A method of forming a coating includes disposing a substrate having a plurality of protrusions on a seal and layering a topcoat over the protrusions. The method of forming a coating also includes creating a wear pattern and converting the topcoat. A turbine section includes a casing, a plurality of blades within the casing, and a substrate deposited on the casing having a plurality of protrusions. The turbine also includes an unconverted topcoat disposed over the plurality of protrusions, the topcoat having segmented portions defining a plurality of faults extending from the protrusions through the topcoat. A method of forming a coating includes creating a channel in the coating during an initial rub event and converting the coating during a high-temperature event. Converting the coating includes preserving the channel created during the initial rub event.
    Type: Grant
    Filed: April 18, 2019
    Date of Patent: July 18, 2023
    Assignee: Raytheon Technologies Corporation
    Inventors: John R. Farris, Michael G. McCaffrey
  • Patent number: 11697994
    Abstract: A gas turbine engine component includes a ceramic matrix composite (CMC) body that includes an interior surface that defines a blind cavity. A barrier coating is disposed on an exterior of the CMC body. A ceramic body in the blind cavity lines at least a portion of the interior surface of the CMC body. The ceramic body defines an open, interconnected network of pores.
    Type: Grant
    Filed: February 7, 2020
    Date of Patent: July 11, 2023
    Assignee: RAYTHEON TECHNOLOGIES CORPORATION
    Inventors: Michael G. McCaffrey, Bryan P. Dube