Patents by Inventor Patrick J. Thrash
Patrick J. Thrash 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: 9278826Abstract: A preform forming machine for producing a three-dimensional dry fiber preform may include a forming block assembly and a clamping plate assembly. The forming block assembly may have a forming table and a forming block and may be positionable in a series of forming block assemblies. The clamping plate assembly may have a clamping table and a clamping plate and may be positionable in a series of clamping plate assemblies arranged in opposing relation to the series of forming block assemblies. Each forming block may be configured to fold a ply stack over onto itself to form a web of a preform. Each clamping plate may be configured to clamp the ply stack to the forming table during the folding of the ply stack.Type: GrantFiled: June 5, 2013Date of Patent: March 8, 2016Assignee: The Boeing CompanyInventors: Patrick J. Thrash, Chad L. Boger, Michael James Farrell
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Publication number: 20140360417Abstract: A preform forming machine for producing a three-dimensional dry fiber preform may include a forming block assembly and a clamping plate assembly. The forming block assembly may have a forming table and a forming block and may be positionable in a series of forming block assemblies. The clamping plate assembly may have a clamping table and a clamping plate and may be positionable in a series of clamping plate assemblies arranged in opposing relation to the series of forming block assemblies. Each forming block may be configured to fold a ply stack over onto itself to form a web of a preform. Each clamping plate may be configured to clamp the ply stack to the forming table during the folding of the ply stack.Type: ApplicationFiled: June 5, 2013Publication date: December 11, 2014Applicant: The Boeing CompanyInventors: Patrick J. THRASH, Chad L. BOGER, Michael James FARRELL
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Patent number: 8906484Abstract: The present disclosure is directed to a composite armor system and method of manufacturing the same including a composite armor system that includes a first bulk bonded fibrous layer, a second bonded fibrous layer bonded to the first bulk bonded fibrous layer and a third bonded fibrous layer. At least one release layer is disposed between the second bonded fibrous layer and the third bonded fibrous layer and a joining mechanism that joins the second bonded fibrous layer to the third bonded fibrous layer through apertures in the release layer into a joined bonded substratum layer. The release layer prevents bonding between the second bonded fibrous layer and the third bonded fibrous layer at opposite portions of the release layer contacting both the second bonded fibrous layer and the third bonded fibrous layer.Type: GrantFiled: May 2, 2012Date of Patent: December 9, 2014Assignee: The Boeing CompanyInventors: Joseph Benson Black, Jr., Patrick J. Thrash, Robert Eugene Turley
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Patent number: 8728263Abstract: A composite structure is provided including a first fabric and a second fabric. A substantially elongate and substantially rigid first member is spaced apart from and coupled with the first fabric via the second fabric. A resin substantially is infused into the first fabric and the second fabric, and substantially encapsulates the first member to form a unitary structure.Type: GrantFiled: July 29, 2011Date of Patent: May 20, 2014Assignee: The Boeing CompanyInventors: Alexander Velicki, Patrick J. Thrash
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Patent number: 8361262Abstract: A method and apparatus for manufacturing. A fiber layer and a porous bonding layer are formed to form a unidirectional lay-up of fibers. The lay-up of fibers is heated under pressure to form a unidirectional composite tape of desired thickness to substantially maintain the fibers in a desired configuration. The unidirectional composite tape is slit to a desired width, and the slit unidirectional composite tape is loaded into a multiaxial fabric machine. A first layer is built from the composite tape in the multiaxial machine, and a second layer is built from the composite tape on the first layer at a predetermined angle from the first layer in the multiaxial machine. The first and second layers are consolidated to form a composite fabric in a continuous process.Type: GrantFiled: November 8, 2007Date of Patent: January 29, 2013Assignee: The Boeing CompanyInventors: Thomas Karl Tsotsis, Patrick J. Thrash, Branko Sarh
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Patent number: 8220588Abstract: The different advantageous embodiments provide an inner barrel structure comprising an outer skin, an inner skin, a number of septa, and a truss core.Type: GrantFiled: March 31, 2010Date of Patent: July 17, 2012Assignee: The Boeing CompanyInventors: Patrick J. Thrash, David Michael Miller
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Publication number: 20110287208Abstract: A composite structure is provided including a first fabric and a second fabric. A substantially elongate and substantially rigid first member is spaced apart from and coupled with the first fabric via the second fabric. A resin substantially is infused into the first fabric and the second fabric, and substantially encapsulates the first member to form a unitary structure.Type: ApplicationFiled: July 29, 2011Publication date: November 24, 2011Applicant: THE BOEING COMPANYInventors: Alexander Velicki, Patrick J. Thrash
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Patent number: 8057721Abstract: A resin infusion mold tool system for use in a vacuum assisted resin transfer molding process with a subsequent pressure bleed step. The mold tool system includes a mold assembly having an outer mold line tool connected to resin supply lines and supplying resin to the preform. A plurality of inner mold line tools form a hard interface with the inner mold line of the fiber preform and are held to within tight tolerances by an external locating fixture. Excess resin is drawn out of the fiber preform using a vacuum bag connected to vacuum lines and disposed over the inner mold line tools but not between the tools and the fiber preform. The mold assembly is placed in an autoclave, the resin supply lines are detached and the autoclave pressurized to bleed additional resin out of the preform to raise the fiber volume of the composite structure.Type: GrantFiled: February 13, 2008Date of Patent: November 15, 2011Assignee: The Boeing CompanyInventors: Patrick J. Thrash, Roger Alan Burgess, Alan M. Markus
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Patent number: 8042767Abstract: A composite structure is provided including a first fabric and a second fabric. A substantially elongate and substantially rigid first member is spaced apart from and coupled with the first fabric via the second fabric. A resin substantially is infused into the first fabric and the second fabric, and substantially encapsulates the first member to form a unitary structure.Type: GrantFiled: September 4, 2007Date of Patent: October 25, 2011Assignee: The Boeing CompanyInventors: Alexander Velicki, Patrick J. Thrash
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Publication number: 20110244150Abstract: The different advantageous embodiments provide an inner barrel structure comprising an outer skin, an inner skin, a number of septa, and a truss core.Type: ApplicationFiled: March 31, 2010Publication date: October 6, 2011Applicant: THE BOEING COMPANYInventors: Patrick J. Thrash, David Michael Miller
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Publication number: 20100276828Abstract: A resin infusion mold tool system for use in a vacuum assisted resin transfer molding process with a subsequent pressure bleed step. The mold tool system includes a mold assembly having an outer mold line tool connected to resin supply lines and supplying resin to the preform. A plurality of inner mold line tools form a hard interface with the inner mold line of the fiber preform and are held to within tight tolerances by an external locating fixture. Excess resin is drawn out of the fiber preform using a vacuum bag connected to vacuum lines and disposed over the inner mold line tools but not between the tools and the fiber preform. The mold assembly is placed in an autoclave, the resin supply lines are detached and the autoclave pressurized to bleed additional resin out of the preform to raise the fiber volume of the composite structure.Type: ApplicationFiled: February 13, 2008Publication date: November 4, 2010Applicant: The Boeing CompanyInventors: Patrick J. Thrash, Roger Alan Burgess, Alan M. Markus
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Publication number: 20090120562Abstract: A method and apparatus for manufacturing. A fiber layer and a porous bonding layer are formed to form a unidirectional lay-up of fibers. The lay-up of fibers is heated under pressure to form a unidirectional composite tape of desired thickness to substantially maintain the fibers in a desired configuration. The unidirectional composite tape is slit to a desired width, and the slit unidirectional composite tape is loaded into a multiaxial fabric machine. A first layer is built from the composite tape in the multiaxial machine, and a second layer is built from the composite tape on the first layer at a predetermined angle from the first layer in the multiaxial machine. The first and second layers are consolidated to form a composite fabric in a continuous process.Type: ApplicationFiled: November 8, 2007Publication date: May 14, 2009Inventors: Thomas Karl Tsotsis, Patrick J. Thrash, Branko Sarh
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Publication number: 20090057487Abstract: A composite structure is provided including a first fabric and a second fabric. A substantially elongate and substantially rigid first member is spaced apart from and coupled with the first fabric via the second fabric. A resin substantially is infused into the first fabric and the second fabric, and substantially encapsulates the first member to form a unitary structure.Type: ApplicationFiled: September 4, 2007Publication date: March 5, 2009Applicant: THE BOEING COMPANYInventors: Alexander Velicki, Patrick J. Thrash
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Patent number: 7413695Abstract: A resin infusion mold tool system for use in a vacuum assisted resin transfer molding process with a subsequent pressure bleed step. The mold tool system includes a mold assembly having an outer mold line tool connected to resin supply lines and supplying resin to the preform. A plurality of inner mold line tools form a hard interface with the inner mold line of the fiber preform and are held to within tight tolerances by an external locating fixture. Excess resin is drawn out of the fiber preform using a vacuum bag connected to vacuum lines and disposed over the inner mold line tools but not between the tools and the fiber preform. The mold assembly is placed in an autoclave, the resin supply lines are detached and the autoclave pressurized to bleed additional resin out of the preform to raise the fiber volume of the composite structure.Type: GrantFiled: January 7, 2004Date of Patent: August 19, 2008Assignee: The Boeing CompanyInventors: Patrick J. Thrash, Roger Alan Burgess, Alan M. Markus
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Patent number: 6840750Abstract: A resin infusion mold tool system for use in a vacuum assisted resin transfer molding process with a subsequent pressure bleed step. The mold tool system includes a mold assembly having an outer mold line tool connected to resin supply lines and supplying resin to the preform. A plurality of inner mold line tools form a hard interface with the inner mold line of the fiber preform and are held to within tight tolerances by an external locating fixture. Excess resin is drawn out of the fiber preform using a vacuum bag connected to vacuum lines and disposed over the inner mold line tools but not between the tools and the fiber preform. The mold assembly is placed in an autoclave, the resin supply lines are detached and the autoclave pressurized to bleed additional resin out of the preform to raise the fiber volume of the composite structure.Type: GrantFiled: June 11, 2001Date of Patent: January 11, 2005Assignee: The Boeing CompanyInventors: Patrick J. Thrash, Roger Alan Burgess, Alan M. Markus
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Publication number: 20040135294Abstract: A resin infusion mold tool system for use in a vacuum assisted resin transfer molding process with a subsequent pressure bleed step. The mold tool system includes a mold assembly having an outer mold line tool connected to resin supply lines and supplying resin to the preform. A plurality of inner mold line tools form a hard interface with the inner mold line of the fiber preform and are held to within tight tolerances by an external locating fixture. Excess resin is drawn out of the fiber preform using a vacuum bag connected to vacuum lines and disposed over the inner mold line tools but not between the tools and the fiber preform. The mold assembly is placed in an autoclave, the resin supply lines are detached and the autoclave pressurized to bleed additional resin out of the preform to raise the fiber volume of the composite structure.Type: ApplicationFiled: January 7, 2004Publication date: July 15, 2004Applicant: The Boeing CompanyInventors: Patrick J. Thrash, Roger Alan Burgess, Alan M. Markus
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Publication number: 20020185785Abstract: A resin infusion mold tool system for use in a vacuum assisted resin transfer molding process with a subsequent pressure bleed step. The mold tool system includes a mold assembly having an outer mold line tool connected to resin supply lines and supplying resin to the preform. A plurality of inner mold line tools form a hard interface with the inner mold line of the fiber preform and are held to within tight tolerances by an external locating fixture. Excess resin is drawn out of the fiber preform using a vacuum bag connected to vacuum lines and disposed over the inner mold line tools but not between the tools and the fiber preform. The mold assembly is placed in an autoclave, the resin supply lines are detached and the autoclave pressurized to bleed additional resin out of the preform to raise the fiber volume of the composite structure.Type: ApplicationFiled: June 11, 2001Publication date: December 12, 2002Applicant: The Boeing CompanyInventors: Patrick J. Thrash, Roger Alan Burgess, Alan M. Markus
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Patent number: 6198983Abstract: Native code for a CNC stitching machine is generated by generating a geometry model of a preform; generating tool paths from the geometry model, the tool paths including stitching instructions for making stitches; and generating additional instructions indicating thickness values. The thickness values are obtained from a lookup table. When the stitching machine runs the native code, it accesses a lookup table to determine a thread tension value corresponding to the thickness value. The stitching machine accesses another lookup table to determine a thread path geometry value corresponding to the thickness value.Type: GrantFiled: December 22, 1997Date of Patent: March 6, 2001Assignee: McDonnell Douglas CorporationInventors: Patrick J. Thrash, Jeffrey L. Miller, Ken Pallas, Robert C. Trank, Rhoda Fox, Mike Korte, Richard Codos, Alexandre Korolev, William Collan
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Patent number: 5931107Abstract: A stitching head for a computer numerically controlled stitching machine includes a thread tensioning mechanism for automatically adjusting thread tension according to the thickness of the material being stitched. The stitching head also includes a mechanism for automatically adjusting thread path geometry according to the thickness of the material being stitched.Type: GrantFiled: December 22, 1997Date of Patent: August 3, 1999Assignee: McDonnell Douglas CorporationInventors: Patrick J. Thrash, Jeffrey L. Miller, Richard Codos
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Patent number: 5915317Abstract: A stitching system includes a gantry that is movable along a material support table. Mounted to the gantry are a plurality of stitching heads and bobbins. The stitching heads are individually controllable in a z-direction, and the bobbins are individually controllable in the z-direction. Each stitching head is paired with a bobbin. Each pair of stitching heads and the bobbins is controlled synchronously in the z-direction. The stitching system is well-suited for stitching preforms of aircraft wing covers and other preforms having variable thickness and compound, contoured three-dimensional surfaces.Type: GrantFiled: December 22, 1997Date of Patent: June 29, 1999Inventors: Patrick J. Thrash, Jeffrey L. Miller, Kenneth G. Pallas, Robert C. Trank, Rhoda Fox, Mike Korte, Richard Codos, Aleksandr Korolev, William Collan