Patents by Inventor Paul Chace Wilcoxson
Paul Chace Wilcoxson 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: 11951658Abstract: Systems and methods for manufacturing a composite member. The system and methods are configured to move different types of composite plies from different supply stations. The composite plies are moved along a conveyance member and then with a transfer station to a forming tool. One or more forming members form the composite plies onto the forming tool.Type: GrantFiled: August 5, 2021Date of Patent: April 9, 2024Assignee: THE BOEING COMPANYInventors: Scott Edward Krajca, Darrell Darwin Jones, Paul Chace Wilcoxson, Kurtis S. Willden, Long Hoang Ly, Daniel R. Smith, Jr., Jeremy Justice
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Patent number: 11780181Abstract: A method includes dispensing a first set of lanes, that each comprise a tow of fiber-reinforced material, at a first angle such that the lanes are placed side-by-side with respect to each other, forming a first layer of a multi-lane tow. The method further includes applying a film directly in contact with multi-lane tow that resists shear forces applied to the multi-lane tow, transporting the multi-lane tow to a mandrel, and compacting the multi-lane tow via a Ply-By-Ply (PBP) machine disposed at the mandrel. The method further comprises removing the film from the multi-lane tow.Type: GrantFiled: November 10, 2021Date of Patent: October 10, 2023Assignee: The Boeing CompanyInventors: Lisa Christina Carlson, Garrett Charles Hanson, Darrell D. Jones, Silas Lawton Studley, Daniel R. Smith, Paul Chace Wilcoxson, Scott Krajca
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Patent number: 11760040Abstract: A tool for making contoured composite hat stringers allows control of stringer wrinkling. The tool includes a set of first openings that allow the tool to flex during contouring of the stringer, and a set of second openings into which portions of the composite charge may strain during the contouring.Type: GrantFiled: September 14, 2021Date of Patent: September 19, 2023Assignee: The Boeing CompanyInventors: Steven Joseph Plummer, Kurtis Shuldberg Willden, Andrew Elmer Modin, Paul Chace Wilcoxson
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Patent number: 11724422Abstract: A system for preparing a bladder for use in manufacturing a composite stringer includes a sock application station, a film application station, and a composite ply application station. The sock application station has a sock cartridge configured to progressively apply a breather sock of breather material in tubular form onto a bladder as the bladder exits the sock cartridge to thereby result in a sock-bladder assembly. The film application station is located downstream of the sock application station and is configured to inflate a film from a flat shape into an open film tube prior to application over the sock-bladder assembly to thereby result in a film-sock-bladder assembly.Type: GrantFiled: May 18, 2020Date of Patent: August 15, 2023Assignee: The Boeing CompanyInventors: Robert W. Whiting, Darrell D. Jones, Paul Chace Wilcoxson, Raviendra S. Suriyaarachchi
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Publication number: 20230201980Abstract: Systems are provided for fabricating a preform for a fuselage section of an aircraft. The system includes advancing a series of arcuate mandrel sections in a process direction through an assembly line, laying up fiber reinforced material onto the arcuate mandrel sections via layup stations, uniting the series of arcuate mandrel sections into a combined mandrel; and splicing the fiber reinforced material laid-up onto the arcuate mandrel sections.Type: ApplicationFiled: February 20, 2023Publication date: June 29, 2023Inventors: Daniel R. Smith, Darrell D. Jones, Paul T. Pritchard, Jason A. Medenciy, Stephen Keith Kirchmeier, Kurtis Shuldberg Willden, Robert William Whiting, Michael Beerman, Raviendra Sidath Suriyaarachchi, Jeremy Evan Justice, Paul Chace Wilcoxson
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Patent number: 11597044Abstract: Systems and methods are provided for fabricating a preform for a fuselage section of an aircraft. The method includes advancing a series of arcuate mandrel sections in a process direction through an assembly line, laying up fiber reinforced material onto the arcuate mandrel sections via layup stations, uniting the series of arcuate mandrel sections into a combined mandrel; and splicing the fiber reinforced material laid-up onto the arcuate mandrel sections.Type: GrantFiled: November 10, 2021Date of Patent: March 7, 2023Assignee: The Boeing CompanyInventors: Daniel R. Smith, Darrell D. Jones, Paul T. Pritchard, Jason A. Medenciy, Stephen Keith Kirchmeier, Kurtis Shuldberg Willden, Robert William Whiting, Michael Beerman, Raviendra Sidath Suriyaarachchi, Jeremy Evan Justice, Paul Chace Wilcoxson
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Patent number: 11390046Abstract: A tubular material application system for applying a tubular material onto an elongate mandrel includes a gripper system including a first gripper and a second gripper configured to move with inchworm-type movement along an elongated mandrel and incrementally apply a tubular material onto the mandrel to thereby result in a tubular material-mandrel assembly.Type: GrantFiled: May 18, 2020Date of Patent: July 19, 2022Assignee: The Boeing CompanyInventors: Darrell D. Jones, Paul Chace Wilcoxson, Raviendra S. Suriyaarachchi
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Publication number: 20220152759Abstract: Systems and methods are provided for fabricating a preform for a fuselage section of an aircraft. The method includes advancing a series of arcuate mandrel sections in a process direction through an assembly line, laying up fiber reinforced material onto the arcuate mandrel sections via layup stations, uniting the series of arcuate mandrel sections into a combined mandrel; and splicing the fiber reinforced material laid-up onto the arcuate mandrel sections.Type: ApplicationFiled: November 10, 2021Publication date: May 19, 2022Inventors: Daniel R. Smith, Darrell D. Jones, Paul T. Pritchard, Jason A. Medenciy, Stephen Keith Kirchmeier, Kurtis Shuldberg Willden, Robert William Whiting, Michael Beerman, Raviendra Sidath Suriyaarachchi, Jeremy Evan Justice, Paul Chace Wilcoxson
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Publication number: 20220153452Abstract: Systems and methods are provided for fabricating a part on a mandrel. The system includes a series of stations divided into at least two groups of stations, wherein each group of stations performs fabrication operations on a particular zone of the mandrel.Type: ApplicationFiled: November 10, 2021Publication date: May 19, 2022Inventors: Daniel R. Smith, Darrell D. Jones, Paul Chace Wilcoxson, Raviendra Sidath Suriyaarachchi, Robert William Whiting, Jeremy Evan Justice
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Publication number: 20220152949Abstract: A method includes dispensing a first set of lanes, that each comprise a tow of fiber-reinforced material, at a first angle such that the lanes are placed side-by-side with respect to each other, forming a first layer of a multi-lane tow. The method further includes applying a film directly in contact with multi-lane tow that resists shear forces applied to the multi-lane tow, transporting the multi-lane tow to a mandrel, and compacting the multi-lane tow via a Ply-By-Ply (PBP) machine disposed at the mandrel. The method further comprises removing the film from the multi-lane tow.Type: ApplicationFiled: November 10, 2021Publication date: May 19, 2022Inventors: Lisa Christina Carlson, Garrett Charles Hanson, Darrell D. Jones, Silas Lawton Studley, Daniel R. Smith, Paul Chace Wilcoxson, Scott Krajca
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Publication number: 20220080680Abstract: A tool for making contoured composite hat stringers allows control of stringer wrinkling. The tool includes a set of first openings that allow the tool to flex during contouring of the stringer, and a set of second openings into which portions of the composite charge may strain during the contouring.Type: ApplicationFiled: September 14, 2021Publication date: March 17, 2022Inventors: Steven Joseph Plummer, Kurtis Shuldberg Willden, Andrew Elmer Modin, Paul Chace Wilcoxson
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Publication number: 20220080622Abstract: Systems and methods for manufacturing a composite member. The system and methods are configured to move different types of composite plies from different supply stations. The composite plies are moved along a conveyance member and then with a transfer station to a forming tool. One or more forming members form the composite plies onto the forming tool.Type: ApplicationFiled: August 5, 2021Publication date: March 17, 2022Inventors: Scott Edward Krajca, Darrell Darwin Jones, Paul Chace Wilcoxson, Kurtis S. Willden, Long Hoang Ly, Daniel R. Smith, JR., Jeremy Justice
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Patent number: 11247413Abstract: Composite parts including hybrid plies, methods of forming the composite parts, and systems for forming the composite parts are disclosed herein. The composite parts include a plurality of plies of composite material. At least one ply is a hybrid ply. The hybrid ply is defined by a plurality of distinct ply tiles, and at least one distinct ply tile in the plurality of distinct ply tiles defines at least one ply tile property that differs from a corresponding ply tile property of at least one other distinct ply tile in the plurality of distinct ply tiles. The methods include selecting at least one distinct ply tile and positioning the at least one distinct ply tile. The methods also include selecting at least one other distinct ply tile and positioning the at least one other distinct ply tile. The systems include systems that define the composite parts and/or perform the methods.Type: GrantFiled: December 17, 2018Date of Patent: February 15, 2022Assignee: The Boeing CompanyInventors: Daniel M. Rotter, Bradley Andrew Coxon, Kurtis S. Willden, Stephen Lee Metschan, Paul Chace Wilcoxson, Joseph Jay Pruss, Darrell D. Jones
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Publication number: 20210354337Abstract: A system for preparing a bladder for use in manufacturing a composite stringer includes a sock application station, a film application station, and a composite ply application station. The sock application station has a sock cartridge configured to progressively apply a breather sock of breather material in tubular form onto a bladder as the bladder exits the sock cartridge to thereby result in a sock-bladder assembly. The film application station is located downstream of the sock application station and is configured to inflate a film from a flat shape into an open film tube prior to application over the sock-bladder assembly to thereby result in a film-sock-bladder assembly.Type: ApplicationFiled: May 18, 2020Publication date: November 18, 2021Inventors: Robert W. Whiting, Darrell D. Jones, Paul Chace Wilcoxson, Raviendra S. Suriyaarachchi
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Publication number: 20210354403Abstract: A tubular material application system for applying a tubular material onto an elongate mandrel includes a gripper system including a first gripper and a second gripper configured to move with inchworm-type movement along an elongated mandrel and incrementally apply a tubular material onto the mandrel to thereby result in a tubular material-mandrel assembly.Type: ApplicationFiled: May 18, 2020Publication date: November 18, 2021Inventors: Darrell D. Jones, Paul Chace Wilcoxson, Raviendra S. Suriyaarachchi
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Patent number: 10807737Abstract: Methods of assembling stiffened composite structures are disclosed. Some methods include forming a stiffener assembly by compacting it within a trough formed in a trunnion. A single trunnion may accommodate two or more different types of stiffeners, thereby avoiding the need for multiple sets of tooling. In some methods, a plurality of stiffener segments may be spliced together, thereby avoiding the need to transport and handle an entire stiffener. A vacuum chuck may be utilized in some examples to transfer the stiffener assembly from the trunnion to a transfer tool. The same vacuum chuck may be transferred along with the stiffener assembly on the transfer tool and loaded onto an inner mold line layup mandrel, where the vacuum chuck may be used to compact the stiffener assembly to the inner mold line layup mandrel.Type: GrantFiled: December 13, 2017Date of Patent: October 20, 2020Assignee: The Boeing CompanyInventors: Paul Chace Wilcoxson, Samuel Ray Stewart, Kurtis Shuldberg Willden
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Publication number: 20200189213Abstract: Composite parts including hybrid plies, methods of forming the composite parts, and systems for forming the composite parts are disclosed herein. The composite parts include a plurality of plies of composite material. At least one ply is a hybrid ply. The hybrid ply is defined by a plurality of distinct ply tiles, and at least one distinct ply tile in the plurality of distinct ply tiles defines at least one ply tile property that differs from a corresponding ply tile property of at least one other distinct ply tile in the plurality of distinct ply tiles. The methods include selecting at least one distinct ply tile and positioning the at least one distinct ply tile. The methods also include selecting a least one other distinct ply tile and positioning the at least one other distinct ply tile. The systems include systems that define the composite parts and/or perform the methods.Type: ApplicationFiled: December 17, 2018Publication date: June 18, 2020Inventors: Daniel M. Rotter, Bradley Andrew Coxon, Kurtis S. Willden, Stephen Lee Metschan, Paul Chace Wilcoxson, Joseph Jay Pruss, Darrell D. Jones
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Publication number: 20180111672Abstract: Methods of assembling stiffened composite structures are disclosed. Some methods include forming a stiffener assembly by compacting it within a trough formed in a trunnion. A single trunnion may accommodate two or more different types of stiffeners, thereby avoiding the need for multiple sets of tooling. In some methods, a plurality of stiffener segments may be spliced together, thereby avoiding the need to transport and handle an entire stiffener. A vacuum chuck may be utilized in some examples to transfer the stiffener assembly from the trunnion to a transfer tool. The same vacuum chuck may be transferred along with the stiffener assembly on the transfer tool and loaded onto an inner mold line layup mandrel, where the vacuum chuck may be used to compact the stiffener assembly to the inner mold line layup mandrel.Type: ApplicationFiled: December 13, 2017Publication date: April 26, 2018Inventors: Paul Chace Wilcoxson, Samuel Ray Stewart, Kurtis Shuldberg Willden
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Patent number: 9873500Abstract: Methods of and systems for assembling stiffened composite structures are disclosed. Some methods include forming a stiffener assembly by compacting it within a trough formed in a trunnion. A single trunnion may accommodate two or more different types of stiffeners, thereby avoiding the need for multiple sets of tooling. In some methods, a plurality of stiffener segments may be spliced together, thereby avoiding the need to transport and handle an entire stiffener. A vacuum chuck may be utilized in some examples to transfer the stiffener assembly from the trunnion to a transfer tool. The same vacuum chuck may be transferred along with the stiffener assembly on the transfer tool and loaded onto an inner mold line layup mandrel, where the vacuum chuck may be used to compact the stiffener assembly to the inner mold line layup mandrel.Type: GrantFiled: September 16, 2014Date of Patent: January 23, 2018Assignee: The Boeing CompanyInventors: Paul Chace Wilcoxson, Samuel Ray Stewart, Kurtis Shuldberg Willden
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Publication number: 20160075092Abstract: Methods of and systems for assembling stiffened composite structures are disclosed. Some methods include forming a stiffener assembly by compacting it within a trough formed in a trunnion. A single trunnion may accommodate two or more different types of stiffeners, thereby avoiding the need for multiple sets of tooling. In some methods, a plurality of stiffener segments may be spliced together, thereby avoiding the need to transport and handle an entire stiffener. A vacuum chuck may be utilized in some examples to transfer the stiffener assembly from the trunnion to a transfer tool. The same vacuum chuck may be transferred along with the stiffener assembly on the transfer tool and loaded onto an inner mold line layup mandrel, where the vacuum chuck may be used to compact the stiffener assembly to the inner mold line layup mandrel.Type: ApplicationFiled: September 16, 2014Publication date: March 17, 2016Applicant: The Boeing CompanyInventors: Paul Chace Wilcoxson, Samuel Ray Stewart, Kurtis Shuldberg Willden