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).

  • Publication number: 20240360771
    Abstract: A blade outer airseal (BOAS) assembly of a gas turbine engine includes a plurality of BOAS segments arrayed circumferentially about the engine central longitudinal axis, and a plurality of BOAS carriers located radially outboard of the plurality of BOAS segments. Each BOAS carrier is supportive of at least one BOAS segment. The BOAS assembly includes plurality of adjustment levers. Each adjustment lever is operably connected to at least two BOAS carriers of the plurality of BOAS carriers. Rotation of each adjustment lever about a respective pivot axis urges movement of the plurality of BOAS segments in a radial direction thereby adjusting a radial gap between the turbine rotor and the plurality of BOAS segments.
    Type: Application
    Filed: April 28, 2023
    Publication date: October 31, 2024
    Inventor: Michael G. McCaffrey
  • Publication number: 20240360772
    Abstract: A blade outer airseal assembly of a gas turbine engine includes a blade outer airseal (BOAS) segment, and a BOAS carrier positioned radially outboard of the BOAS segment relative to an engine central longitudinal axis. The BOAS segment is secured to the BOAS carrier, and an adjustment lever is operably connected to the BOAS carrier. Rotation of the adjustment lever about a pivot axis at a pivot urges movement of the BOAS segment in a radial direction.
    Type: Application
    Filed: April 28, 2023
    Publication date: October 31, 2024
    Inventor: Michael G. McCaffrey
  • Patent number: 12110839
    Abstract: A variable area nozzle assembly includes a fixed center plug, a fixed outer nozzle, and an inner nozzle. The fixed center plug includes a seal. The inner nozzle is disposed between the fixed center plug and the fixed outer nozzle. The inner nozzle includes an inner nozzle body. The inner nozzle body forms a primary duct between the inner nozzle and the fixed outer nozzle. The inner nozzle body forms a secondary duct and a gap. The gap is a nozzle outlet of the secondary duct. The secondary duct is disposed between the inner nozzle body and the fixed center plug upstream of the seal. The inner nozzle body forms a plurality of apertures. The inner nozzle body is translatable between a first position and a second position. In the first position, the primary duct has a first cross-sectional area and the plurality of apertures are isolated from the gap by the seal.
    Type: Grant
    Filed: December 22, 2023
    Date of Patent: October 8, 2024
    Assignee: RTX Corporation
    Inventors: Michael G. McCaffrey, Nathan L. Messersmith
  • Patent number: 12065937
    Abstract: A variable area nozzle assembly includes a fixed center plug, a fixed outer nozzle, and an inner nozzle. The fixed center plug includes a plug body and a protrusion. The fixed outer nozzle extends about the fixed center plug. The inner nozzle extends about the fixed center plug. The inner nozzle is disposed between the fixed center plug and the fixed outer nozzle. The inner nozzle forms a primary duct between the inner nozzle and the fixed outer nozzle. The primary duct includes an exit plane. The inner nozzle body forms a secondary duct and a gap. The gap is a nozzle outlet of the secondary duct. The gap includes a gap inlet and a gap outlet. The gap inlet is disposed upstream of the protrusion. The gap outlet is disposed downstream of the protrusion. The inner nozzle body is translatable between a first position and a second position. In the first position, the primary duct has a first area at the exit plane and the inner nozzle body is disposed at the protrusion.
    Type: Grant
    Filed: December 22, 2023
    Date of Patent: August 20, 2024
    Assignee: RTX Corporation
    Inventors: Michael G. McCaffrey, Nathan L. Messersmith
  • Patent number: 12060806
    Abstract: Tangential onboard injector assemblies include a TOBI and a TOBI blocker assembly arranged upstream of an inlet of the TOBI. The TOBI blocker assembly includes a first blocker plate upstream from the inlet and defining a blocker cavity between the first blocker plate and the TOBI. The first blocker plate includes a blocking portion and a filter portion to permit airflow therethrough. A second blocker plate is arranged within the blocker cavity to obstruct a flow of air containing particulate matter and a gap is present between the second blocker plate and the first blocker plate to permit flow of air around the second blocker plate. A third blocker plate is arranged downstream from the second blocker plate within the blocker cavity and includes a feed hole. Air within a region between the second blocker plate and the third blocker plate flows through the feed hole into the TOBI.
    Type: Grant
    Filed: August 16, 2023
    Date of Patent: August 13, 2024
    Assignee: RTX CORPORATION
    Inventor: Michael G. McCaffrey
  • Patent number: 12055045
    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: Grant
    Filed: December 4, 2023
    Date of Patent: August 6, 2024
    Assignee: RTX CORPORATION
    Inventor: Michael G. McCaffrey
  • Patent number: 12012858
    Abstract: A blade outer airseal (BOAS) assembly of a gas turbine engine includes a BOAS segment, and a BOAS carrier located radially outboard of the BOAS segment relative to an engine central longitudinal axis. The BOAS segment secured to the BOAS carrier. The BOAS assembly is selectably radially movable during operation of the gas turbine engine. One or more secondary retention features are configured to limit the radial movement of the BOAS assembly.
    Type: Grant
    Filed: April 28, 2023
    Date of Patent: June 18, 2024
    Assignee: RTX CORPORATION
    Inventor: Michael G. McCaffrey
  • Patent number: 12000306
    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: Grant
    Filed: June 3, 2022
    Date of Patent: June 4, 2024
    Assignee: RTX CORPORATION
    Inventor: Michael G. McCaffrey
  • 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: 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: 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: 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