Patents by Inventor Michael P. Appleby
Michael P. Appleby 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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Patent number: 10207315Abstract: Certain exemplary embodiments can provide a composition, system, machine, device, manufacture, circuit, and/or user interface adapted for, and/or a method and/or machine-readable medium comprising machine-implementable instructions for, activities that can comprise, after removing a cast device from a stack-lamination-derived mold, said cast device formed from a molding composition, applying a desired shape to said cast device to form a shaped cast device, said molding composition comprising: a ceramic composition comprising silica; an cycloaliphatic epoxy binder composition, said cycloaliphatic epoxy binder composition present in said molding composition in an amount up to 30% by weight of said molding composition; a silicone composition comprising a siloxane resin, said silicone composition present in said molding composition in an amount up to 30% by weight of said molding composition; and a solvent composition adapted to dissolve said cycloaliphatic epoxy binder composition and said silicone composition.Type: GrantFiled: November 9, 2015Date of Patent: February 19, 2019Assignee: UNITED TECHNOLOGIES CORPORATIONInventors: Michael P. Appleby, Iain Fraser, John Paulus
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Patent number: 10189184Abstract: In certain exemplary embodiments of the present invention, three-dimensional micro-mechanical devices and/or micro-structures can be made using a production casting process. As part of this process, an intermediate mold can be made from or derived from a precision stack lamination and used to fabricate the devices and/or structures. Further, the micro-devices and/or micro-structures can be fabricated on planar or nonplanar surfaces through use of a series of production casting processes and intermediate molds. The use of precision stack lamination can allow the fabrication of high aspect ratio structures. Moreover, via certain molding and/or casting materials, molds having cavities with protruding undercuts also can be fabricated.Type: GrantFiled: July 16, 2009Date of Patent: January 29, 2019Assignee: UNITED TECHNOLOGIES CORPORATIONInventors: Michael P. Appleby, Iain Fraser, James E. Atkinson
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Publication number: 20160082502Abstract: Certain exemplary embodiments can provide a composition, system, machine, device, manufacture, circuit, and/or user interface adapted for, and/or a method and/or machine-readable medium comprising machine-implementable instructions for, activities that can comprise, after removing a cast device from a stack-lamination-derived mold, said cast device formed from a molding composition, applying a desired shape to said cast device to form a shaped cast device, said molding composition comprising: a ceramic composition comprising silica; an cycloaliphatic epoxy binder composition, said cycloaliphatic epoxy binder composition present in said molding composition in an amount up to 30% by weight of said molding composition; a silicone composition comprising a siloxane resin, said silicone composition present in said molding composition in an amount up to 30% by weight of said molding composition; and a solvent composition adapted to dissolve said cycloaliphatic epoxy binder composition and said silicone composition.Type: ApplicationFiled: November 9, 2015Publication date: March 24, 2016Inventors: Michael P. Appleby, Iain Fraser, John Paulus
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Patent number: 9272324Abstract: An investment casting process for a hollow component such as a gas turbine blade utilizing a ceramic core (10) that is cast in a flexible mold (24) using a low pressure, vibration assisted casting process. The flexible mold is cast from a master tool (14) machined from soft metal using a relatively low precision machining process, with relatively higher precision surfaces being defined by a precision formed insert (22) incorporated into the master tool. A plurality of identical flexible molds may be formed from a single master tool in order to permit the production of ceramic cores at a desired rate with a desired degree of part-to-part precision.Type: GrantFiled: December 7, 2010Date of Patent: March 1, 2016Assignees: Siemens Energy, Inc., Mikro Systems, Inc.Inventors: Gary B. Merrill, Andrew J. Burns, Michael P. Appleby, Iain A. Fraser, John R. Paulus
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Patent number: 9208916Abstract: In certain exemplary embodiments of the present invention, three-dimensional micro-mechanical devices and/or micro-structures can be made using a production casting process. As part of this process, an intermediate mold can be made from or derived from a precision stack lamination and used to fabricate the devices and/or structures. Further, the micro-devices and/or micro-structures can be fabricated on planar or nonplanar surfaces through use of a series of production casting processes and intermediate molds. The use of precision stack lamination can allow the fabrication of high aspect ratio structures. Moreover, via certain molding and/or casting materials, molds having cavities with protruding undercuts also can be fabricated.Type: GrantFiled: June 18, 2008Date of Patent: December 8, 2015Assignee: Mikro Systems, Inc.Inventors: Michael P. Appleby, Iain Fraser, James E. Atkinson
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Patent number: 9208917Abstract: In certain exemplary embodiments of the present invention, three-dimensional micro-mechanical devices and/or micro-structures can be made using a production casting process. As part of this process, an intermediate mold can be made from or derived from a precision stack lamination and used to fabricate the devices and/or structures. Further, the micro-devices and/or micro-structures can be fabricated on planar or nonplanar surfaces through use of a series of production casting processes and intermediate molds. The use of precision stack lamination can allow the fabrication of high aspect ratio structures. Moreover, via certain molding and/or casting materials, molds having cavities with protruding undercuts also can be fabricated.Type: GrantFiled: December 22, 2009Date of Patent: December 8, 2015Assignee: Mikro Systems, Inc.Inventors: Michael P. Appleby, Iain Fraser, James E. Atkinson
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Patent number: 9129716Abstract: In certain exemplary embodiments of the present invention, three-dimensional micro-mechanical devices and/or micro-structures can be made using a production casting process. As part of this process, an intermediate mold can be made from or derived from a precision stack lamination and used to fabricate the devices and/or structures. Further, the micro-devices and/or micro-structures can be fabricated on planar or nonplanar surfaces through use of a series of production casting processes and intermediate molds. The use of precision stack lamination can allow the fabrication of high aspect ratio structures. Moreover, via certain molding and/or casting materials, molds having cavities with protruding undercuts also can be fabricated.Type: GrantFiled: December 22, 2009Date of Patent: September 8, 2015Assignee: Mikro Systems, Inc.Inventors: Michael P. Appleby, Iain Fraser, James E. Atkinson
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Patent number: 8940210Abstract: In certain exemplary embodiments of the present invention, three-dimensional micro-mechanical devices and/or micro-structures can be made using a production casting process. As part of this process, an intermediate mold can be made from or derived from a precision stack lamination and used to fabricate the devices and/or structures. Further, the micro-devices and/or micro-structures can be fabricated on planar or nonplanar surfaces through use of a series of production casting processes and intermediate molds. The use of precision stack lamination can allow the fabrication of high aspect ratio structures. Moreover, via certain molding and/or casting materials, molds having cavities with protruding undercuts also can be fabricated. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure.Type: GrantFiled: September 9, 2010Date of Patent: January 27, 2015Assignee: Mikro Systems, Inc.Inventors: Michael P. Appleby, Iain Fraser, James E. Atkinson
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Publication number: 20140241938Abstract: A ceramic casting vessel (92) including an insert (94) extending between a shell (91) and a core (93) of the vessel to define a cooling channel of an alloy component cast therein. The insert may include a portion (96) running generally parallel to a surface of the shell to define a cooling channel running generally parallel to a surface of the component. Ends of the insert may be disposed in respective grooves (95, 97) formed in the shell and/or core.Type: ApplicationFiled: May 2, 2014Publication date: August 28, 2014Applicant: SIEMENS ENERGY, INC.Inventors: Gary B. Merrill, MIchael P. Appleby, Iain Alasdair Fraser, Jill Klinger, John R. Paulus
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Patent number: 8678771Abstract: A method of manufacturing a component, including providing a three-dimensional computer model of the component to be produced; deconstructing the three-dimensional computer model by defining a plurality of model slices; forming a plurality of metallic foils, where each foil corresponds to a specific model slice; assembling the plurality of formed foils in a tool to form a three-dimensional component stack; and bonding the three-dimensional component stack to form the component. Characteristics of the foils may differ in various portions of the stack, such as being a different material, having a different thickness, or having a different grain orientation. The control of dimensional tolerances of internal structures, such as cooling passages, in three dimensions is devolved into two separate steps of 1) selecting a thickness of each slice/foil, and 2) controlling in two dimensions a material removal process applied to the respective foil.Type: GrantFiled: December 14, 2009Date of Patent: March 25, 2014Assignees: Siemens Energy, Inc., Mikro Systems, Inc.Inventors: Gary B. Merrill, Andrew J. Burns, Michael P. Appleby, Iain Alasdair Fraser, John R. Paulus
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Publication number: 20140034838Abstract: In certain exemplary embodiments of the present invention, three-dimensional micro-mechanical devices and/or micro-structures can be made using a production casting process. As part of this process, an intermediate mold can be made from or derived from a precision stack lamination and used to fabricate the devices and/or structures. Further, the micro-devices and/or micro-structures can be fabricated on planar or nonplanar surfaces through use of a series of production casting processes and intermediate molds. The use of precision stack lamination can allow the fabrication of high aspect ratio structures. Moreover, via certain molding and/or casting materials, molds having cavities with protruding undercuts also can be fabricated. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure.Type: ApplicationFiled: October 9, 2013Publication date: February 6, 2014Applicant: Mikro Systems, Inc.Inventors: Michael P. Appleby, Iain Fraser, James E. Atkinson
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Patent number: 8598553Abstract: In certain exemplary embodiments of the present invention, three-dimensional micro-mechanical devices and/or micro-structures can be made using a production casting process. As part of this process, an intermediate mold can be made from or derived from a precision stack lamination and used to fabricate the devices and/or structures. Further, the micro-devices and/or micro-structures can be fabricated on planar or nonplanar surfaces through use of a series of production casting processes and intermediate molds. The use of precision stack lamination can allow the fabrication of high aspect ratio structures. Moreover, via certain molding and/or casting materials, molds having cavities with protruding undercuts also can be fabricated.Type: GrantFiled: August 31, 2011Date of Patent: December 3, 2013Assignee: Mikro Systems, Inc.Inventors: Michael P. Appleby, Iain Fraser, James E. Atkinson
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Patent number: 8540913Abstract: In certain exemplary embodiments of the present invention, three-dimensional micro-mechanical devices and/or micro-structures can be made using a production casting process. As part of this process, an intermediate mold can be made from or derived from a precision stack lamination and used to fabricate the devices and/or structures. Further, the micro-devices and/or micro-structures can be fabricated on planar or nonplanar surfaces through use of a series of production casting processes and intermediate molds. The use of precision stack lamination can allow the fabrication of high aspect ratio structures. Moreover, via certain molding and/or casting materials, molds having cavities with protruding undercuts also can be fabricated. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure.Type: GrantFiled: October 31, 2007Date of Patent: September 24, 2013Assignee: Mikro Systems, Inc.Inventors: Michael P. Appleby, Iain Fraser, James E. Atkinson
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Patent number: 8196640Abstract: A core-in-a-core casting method and hybrid core (40) for use in the method. An inner core (42) formed of process-inert particles disposed in a binder material is used as a mold for casting an outer core ((44) formed of particles that will sinter during a subsequent firing step. The inner core provides mechanical support for the outer core during the firing step, and during which the inner core devolves into compacted but unbonded particles that can be removed conveniently from the outer core following the firing step to reveal the fired hollow outer core (44).Type: GrantFiled: July 1, 2011Date of Patent: June 12, 2012Assignee: Mikro Systems, Inc.Inventors: John R. Paulus, Michael P. Appleby
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Publication number: 20120138252Abstract: A core-in-a-core casting method and hybrid core (40) for use in the method. An inner core (42) formed of process-inert particles disposed in a binder material is used as a mold for casting an outer core ((44) formed of particles that will sinter during a subsequent firing step. The inner core provides mechanical support for the outer core during the firing step, and during which the inner core devolves into compacted but unbonded particles that can be removed conveniently from the outer core following the firing step to reveal the fired hollow outer core (44).Type: ApplicationFiled: July 1, 2011Publication date: June 7, 2012Applicant: Mikro Systems, Inc.Inventors: John R. Paulus, Michael P. Appleby
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Publication number: 20110309250Abstract: In certain exemplary embodiments of the present invention, three-dimensional micro-mechanical devices and/or micro-structures can be made using a production casting process. As part of this process, an intermediate mold can be made from or derived from a precision stack lamination and used to fabricate the devices and/or structures. Further, the micro-devices and/or micro-structures can be fabricated on planar or nonplanar surfaces through use of a series of production casting processes and intermediate molds. The use of precision stack lamination can allow the fabrication of high aspect ratio structures. Moreover, via certain molding and/or casting materials, molds having cavities with protruding undercuts also can be fabricated. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure.Type: ApplicationFiled: August 31, 2011Publication date: December 22, 2011Applicant: Mikro Systems, Inc.Inventors: Michael P. Appleby, Iain Fraser, James E. Atkinson
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Patent number: 8062023Abstract: In certain exemplary embodiments of the present invention, three-dimensional micro-mechanical devices and/or micro-structures can be made using a production casting process. As part of this process, an intermediate mold can be made from or derived from a precision stack lamination and used to fabricate the devices and/or structures. Further, the micro-devices and/or micro-structures can be fabricated on planar or nonplanar surfaces through use of a series of production casting processes and intermediate molds. The use of precision stack lamination can allow the fabrication of high aspect ratio structures. Moreover, via certain molding and/or casting materials, molds having cavities with protruding undercuts also can be fabricated. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure.Type: GrantFiled: June 13, 2008Date of Patent: November 22, 2011Assignee: Mikro Systems, Inc.Inventors: Michael P. Appleby, Iain Fraser, James E. Atkinson
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Patent number: 8049193Abstract: Certain exemplary embodiments can provide a first isogrid defining a first plurality of zones, each zone from said first plurality of zones comprising a plurality of ligaments, each zone from said first plurality of zones defining a plurality of spaces, each space bounded by a first sub-plurality of ligaments from said plurality of ligaments, each of said ligaments comprising a plurality of ligament surfaces.Type: GrantFiled: December 22, 2009Date of Patent: November 1, 2011Assignee: Mikro Systems, Inc.Inventors: Michael P. Appleby, William T. Randolph, Jill E. Klinger
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Publication number: 20110204205Abstract: A turbine engine component, such as a turbine blade or vane, with complex internal features can be cast using a core having a first region with normal resolution features and a second region with high resolution features. The core can be formed from a single structure. Alternatively, the first region can be defined by a first ceramic core piece, which can be formed by any conventional process, such as by injection molding or transfer molding. The second region can be defined by a second ceramic core piece formed separately by a method effective to produce high resolution features, such as tomo lithographic molding. The first core piece and the second core piece can be joined by interlocking engagement, such as by male and female dovetails. The high resolution features can be effective to produce high efficiency internal cooling features in the cast component.Type: ApplicationFiled: February 25, 2010Publication date: August 25, 2011Inventors: Ahmed Kamel, Dhafer Jouini, Gary B. Merrill, John R. Paulus, Michael P. Appleby, Iain Alasdair Fraser, Jill Klinger, Gabriel Victor Orsinger, Daniel Ellgass
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Publication number: 20110132563Abstract: An investment casting process for a hollow component such as a gas turbine blade utilizing a ceramic core (10) that is cast in a flexible mold (24) using a low pressure, vibration assisted casting process. The flexible mold is cast from a master tool (14) machined from soft metal using a relatively low precision machining process, with relatively higher precision surfaces being defined by a precision formed insert (22) incorporated into the master tool. A plurality of identical flexible molds may be formed from a single master tool in order to permit the production of ceramic cores at a desired rate with a desired degree of part-to-part precision.Type: ApplicationFiled: December 7, 2010Publication date: June 9, 2011Inventors: Gary B. Merrill, Andrew J. Burns, Michael P. Appleby, Iain A. Fraser, John R. Paulus