Patents by Inventor Michael R. Chapman
Michael R. Chapman 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: 11433575Abstract: A composite charge is positioned onto lower plates of a plurality of placement end effectors. Upper plates of the plurality of placement end effectors are rotated along a first axis to cover the composite charge. The composite charge is contoured to a tool using the plurality of placement end effectors to form a contoured composite charge. The contoured composite charge is compacted using a roller.Type: GrantFiled: May 23, 2019Date of Patent: September 6, 2022Assignee: The Boeing CompanyInventor: Michael R. Chapman
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Publication number: 20200346376Abstract: A composite charge is positioned onto lower plates of a plurality of placement end effectors. Upper plates of the plurality of placement end effectors are rotated along a first axis to cover the composite charge. The composite charge is contoured to a tool using the plurality of placement end effectors to form a contoured composite charge. The contoured composite charge is compacted using a roller.Type: ApplicationFiled: May 23, 2019Publication date: November 5, 2020Inventor: Michael R. Chapman
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Patent number: 10780655Abstract: A tooling apparatus may include a pair of elongated tooling dies independently rotatable about a common central axis. Each tooling die may have a layup surface including a web layup surface and at least one flange layup surface oriented non-parallel to the web layup surface and configured to receive at least one composite ply to form a stringer layup half having a web and at least one flange. The tooling dies may be rotatable into side-by-side relation causing the webs of the stringer layup halves to be positioned in back-to-back mating contact with one another.Type: GrantFiled: October 28, 2015Date of Patent: September 22, 2020Assignee: The Boeing CompanyInventor: Michael R. Chapman
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Patent number: 10661495Abstract: A method and apparatus is presented. Layers of composite material are laid down on a forming tool. A respective bend is formed in each of the layers to form the composite filler comprising bent layers on the forming tool. The composite filler comprising the bent layers is placed into a gap formed by at least one composite structure.Type: GrantFiled: January 19, 2017Date of Patent: May 26, 2020Assignee: The Boeing CompanyInventors: Michael R. Chapman, Khanh Mai Pham, Derek Paul Vetter
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Patent number: 10328616Abstract: A method and apparatus are provided. A composite charge is positioned onto lower plates of a plurality of placement end effectors. Upper plates of the plurality of placement end effectors are rotated along a first axis to cover the composite charge. The composite charge is contoured to a tool using the plurality of placement end effectors to form a contoured composite charge. The contoured composite charge is compacted using a roller.Type: GrantFiled: March 16, 2016Date of Patent: June 25, 2019Assignee: The Boeing CompanyInventor: Michael R. Chapman
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Publication number: 20170266852Abstract: A method and apparatus are provided. A composite charge is positioned onto lower plates of a plurality of placement end effectors. Upper plates of the plurality of placement end effectors are rotated along a first axis to cover the composite charge. The composite charge is contoured to a tool using the plurality of placement end effectors to form a contoured composite charge. The contoured composite charge is compacted using a roller.Type: ApplicationFiled: March 16, 2016Publication date: September 21, 2017Inventor: Michael R. Chapman
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Publication number: 20170129192Abstract: A method and apparatus is presented. Layers of composite material are laid down on a forming tool. A respective bend is formed in each of the layers to form the composite filler comprising bent layers on the forming tool. The composite filler comprising the bent layers is placed into a gap formed by at least one composite structure.Type: ApplicationFiled: January 19, 2017Publication date: May 11, 2017Inventors: Michael R. Chapman, Khanh Mai Pham, Derek Paul Vetter
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Publication number: 20170120541Abstract: A tooling apparatus may include a pair of elongated tooling dies independently rotatable about a common central axis. Each tooling die may have a layup surface including a web layup surface and at least one flange layup surface oriented non-parallel to the web layup surface and configured to receive at least one composite ply to form a stringer layup half having a web and at least one flange. The tooling dies may be rotatable into side-by-side relation causing the webs of the stringer layup halves to be positioned in back-to-back mating contact with one another.Type: ApplicationFiled: October 28, 2015Publication date: May 4, 2017Inventor: Michael R. Chapman
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Patent number: 9623641Abstract: A method and apparatus for reinforcing an end portion of a deformable tool configured for use in forming a composite object. An insert may be placed within a hollow portion of the end portion of the deformable tool in which the insert substantially conforms to a cross-sectional shape and a size of the hollow portion of the end portion of the deformable tool. A side of the end portion of the deformable tool may be reinforced by the insert located within the hollow portion of the end portion of the deformable tool during a curing process used to form the composite object.Type: GrantFiled: September 24, 2013Date of Patent: April 18, 2017Assignee: THE BOEING COMPANYInventors: Michael R. Chapman, Khanh M. Pham
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Patent number: 9566739Abstract: A method and apparatus is presented. Layers of composite material are laid down on a forming tool. A respective bend is formed in each of the layers to form the composite filler comprising bent layers on the forming tool. The composite filler comprising the bent layers is placed into a gap formed by at least one composite structure.Type: GrantFiled: February 18, 2014Date of Patent: February 14, 2017Assignee: THE BOEING COMPANYInventors: Michael R. Chapman, Khanh Mai Pham, Derek Paul Vetter
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Patent number: 9387628Abstract: Method and tooling apparatus for forming a composite charge into a stringer having an I-shaped cross-section. A substantially flat composite charge is placed on a die set and pressed formed into a die set cavity to form a stringer hat. A stringer base is formed by press forming the composite charge against the die set. The die set is used to compress the stringer hat into a stringer web having a bulb on one end thereof. A stringer cap is formed by press forming the bulb within a recess in the die set.Type: GrantFiled: March 19, 2014Date of Patent: July 12, 2016Assignee: THE BOEING COMPANYInventors: Michael R. Chapman, Khanh M. Pham
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Patent number: 9254619Abstract: Method and tooling apparatus for forming a composite charge into a contoured composite blade stringer including an elongate punch and an elongate die flexible along their lengths. The charge is press formed by using the punch to drive the charge into the die. The punch and the die are mounted between a pair of flexible plates. A press coupled with the plates contours the charge by bending the plates into a desired contour. The stringer is allowed to cool down to room temperature while being constrained, before withdrawing the stringer from the tooling apparatus in order to reduce wrinkling.Type: GrantFiled: June 13, 2013Date of Patent: February 9, 2016Assignee: THE BOEING COMPANYInventors: Daniel M. Rotter, Michael R. Chapman, Brad A. Coxon, Paul E. Nelson, Khanh M. Pham
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Publication number: 20150231848Abstract: A method and apparatus is presented. Layers of composite material are laid down on a forming tool. A respective bend is formed in each of the layers to form the composite filler comprising bent layers on the forming tool. The composite filler comprising the bent layers is placed into a gap formed by at least one composite structure.Type: ApplicationFiled: February 18, 2014Publication date: August 20, 2015Applicant: The Boeing CompanyInventors: Michael R. Chapman, Khanh Mai Pham, Derek Paul Vetter
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Publication number: 20140203477Abstract: Method and tooling apparatus for forming a composite charge into a stringer having an I-shaped cross-section. A substantially flat composite charge is placed on a die set and pressed formed into a die set cavity to form a stringer hat. A stringer base is formed by press forming the composite charge against the die set. The die set is used to compress the stringer hat into a stringer web having a bulb on one end thereof. A stringer cap is formed by press forming the bulb within a recess in the die set.Type: ApplicationFiled: March 19, 2014Publication date: July 24, 2014Applicant: The Boeing CompanyInventors: Michael R. Chapman, Khanh M. Pham
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Publication number: 20130340928Abstract: Method and tooling apparatus for forming a composite charge into a contoured composite blade stringer including an elongate punch and an elongate die flexible along their lengths. The charge is press formed by using the punch to drive the charge into the die. The punch and the die are mounted between a pair of flexible plates. A press coupled with the plates contours the charge by bending the plates into a desired contour. The stringer is allowed to cool down to room temperature while being constrained, before withdrawing the stringer from the tooling apparatus in order to reduce wrinkling.Type: ApplicationFiled: June 13, 2013Publication date: December 26, 2013Inventors: Daniel M. Rotter, Michael R. Chapman, Brad A. Coxon, Paul E. Nelson, Khanh M. Pham
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Patent number: 8465613Abstract: Tooling apparatus for forming a composite charge into a contoured composite blade stringer includes an elongate punch and an elongate die flexible along their lengths. The charge is press formed by using the punch to drive the charge into the die. The punch and the die are mounted between a pair of flexible plates. A press coupled with the plates contours the charge by bending the plates into a desired contour.Type: GrantFiled: August 24, 2011Date of Patent: June 18, 2013Assignee: The Boeing CompanyInventors: Daniel M. Rotter, Michael R. Chapman, Brad A. Coxon, Paul E. Nelson
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Patent number: 8418740Abstract: Composite sections for aircraft fuselages and other structures, and methods and systems for manufacturing such sections, are disclosed herein. A method for manufacturing a shell structure in accordance with one embodiment of the invention includes applying composite material to an interior mold surface of a tool to form a skin extending 360 degrees around an axis. The method can further include positioning a plurality of stiffeners on an inner surface of the skin. After the stiffeners have been positioned, a vacuum bag can be installed over the stiffeners and evacuated to press the stiffeners and the skin outwardly against the interior mold surface of the tool. Next, the skin/stiffener combination can be cocured to bond the stiffeners to the skin and harden the shell structure.Type: GrantFiled: September 21, 2012Date of Patent: April 16, 2013Assignee: The Boeing CompanyInventors: Michael R. Chapman, Robert M. Watson, Donald A. Anderson, Marc J. Piehl, Joseph L. Sweetin, Douglas L. Grose
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Publication number: 20130049258Abstract: Tooling apparatus for forming a composite charge into a contoured composite blade stringer includes an elongate punch and an elongate die flexible along their lengths. The charge is press formed by using the punch to drive the charge into the die. The punch and the die are mounted between a pair of flexible plates. A press coupled with the plates contours the charge by bending the plates into a desired contour.Type: ApplicationFiled: August 24, 2011Publication date: February 28, 2013Applicant: THE BOEING COMPANYInventors: Daniel M. Rotter, Michael R. Chapman, Brad A. Coxon, Paul E. Nelson
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Patent number: 8303758Abstract: Methods for manufacturing composite sections for aircraft fuselages and other structures are disclosed herein. A method for manufacturing a shell structure in accordance with one embodiment of the invention includes applying composite material to an interior mold surface of a tool to form a skin extending 360 degrees around an axis. The method can further include positioning a plurality of stiffeners on an inner surface of the skin. After the stiffeners have been positioned, a vacuum bag can be installed over the stiffeners and evacuated to press the stiffeners and the skin outwardly against the interior mold surface of the tool. Next, the skin/stiffener combination can be cocured to bond the stiffeners to the skin and harden the shell structure.Type: GrantFiled: March 30, 2012Date of Patent: November 6, 2012Assignee: The Boeing CompanyInventors: Michael R. Chapman, Robert M. Watson, Donald A. Anderson, Marc J. Piehl, Joseph L. Sweetin, Douglas L. Grose
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Publication number: 20120180942Abstract: Composite sections for aircraft fuselages and other structures, and methods and systems for manufacturing such sections, are disclosed herein. A method for manufacturing a shell structure in accordance with one embodiment of the invention includes applying composite material to an interior mold surface of a tool to form a skin extending 360 degrees around an axis. The method can further include positioning a plurality of stiffeners on an inner surface of the skin. After the stiffeners have been positioned, a vacuum bag can be installed over the stiffeners and evacuated to press the stiffeners and the skin outwardly against the interior mold surface of the tool. Next, the skin/stiffener combination can be cocured to bond the stiffeners to the skin and harden the shell structure.Type: ApplicationFiled: March 30, 2012Publication date: July 19, 2012Applicant: THE BOEING COMPANYInventors: Michael R. Chapman, Robert M. Watson, Donald A. Anderson, Marc J. Piehl, Joseph L. Sweetin, Douglas L. Grose