Patents by Inventor Randall D. Wilkerson

Randall D. Wilkerson 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: 20240336019
    Abstract: An apparatus is provided for forming a braided preform with a desired shape. The apparatus comprises a layup mandrel having a central portion interconnecting opposite end portions. The apparatus also comprises a braidable wheel disposed at one end portion of the layup mandrel and arranged to receive braiding material for a braided layer to be formed on the layup mandrel. The apparatus further comprises a pressure-application device disposed at the other end portion of the layup mandrel and arranged to apply mechanical pressure to the braided layer on the layup mandrel to thereby form the braided preform.
    Type: Application
    Filed: December 13, 2023
    Publication date: October 10, 2024
    Applicant: The Boeing Company
    Inventors: Pedro P. Martin, Gregory J. Hickman, Emma L. Morrissey, Randall D. Wilkerson
  • Patent number: 11724420
    Abstract: Systems and methods are provided for creating precursors for consolidating composite parts. One embodiment is a method for forming a metallic structure. The method includes forming a precursor for a pressure membrane that includes a contour having a linearized length corresponding with a linearized length of a surface of a forming tool. The method also includes affixing a perimeter of the precursor to a perimeter of a base member, leaving a volume between the base member and the precursor, altering a shape of the precursor at a superplastic temperature by forcing the precursor into complementary contact with the surface of the forming tool, and setting the shape of the precursor while the precursor is held in complementary contact.
    Type: Grant
    Filed: November 29, 2018
    Date of Patent: August 15, 2023
    Assignee: The Boeing Company
    Inventors: Marc R. Matsen, Lee Charles Firth, Randall D. Wilkerson, Julie F. Murphy, Ravi Verma
  • Publication number: 20230234327
    Abstract: At least one braided composite layer configured to form a first ply may be provided. A plurality of slit tapes may be arranged and aligned such that each slit tape is adjacent to one another and non-overlapping, to form a second ply. A hybrid composite laminate may be formed by stacking a plurality of plies that includes at least one first ply and at least one second ply. Each slit tape may be a steered unidirectional composite slit tape that is aligned along an axis, contour line, or curve of the hybrid composite laminate, a mold/tooling used to shape the laminate, or the resulting composite part. Hybrid composite laminates may be formed by stacking at least one first ply formed of a braided composite layer and at least one second ply formed from a plurality of slit tapes. Composite parts may be formed by consolidating such hybrid composite laminates.
    Type: Application
    Filed: September 21, 2022
    Publication date: July 27, 2023
    Inventors: Pedro P. Martín, Amol Ogale, Alexander Rubin, Randall D. Wilkerson
  • Patent number: 11559954
    Abstract: A tool for forming a part includes a first tool portion including a first tool surface. The tool further includes a second tool portion comprising a second tool surface facing the first tool surface, wherein the first tool surface and the second tool surface define a tool chamber for forming the part. The tool further includes a bladder subassembly disposed in the tool chamber between the first tool surface and the second tool surface. The bladder subassembly includes a plurality of inner bladders disposed within tool chamber, wherein each inner bladder of the plurality of inner bladders includes an inner bladder chamber that is independently inflatable to selectively apply pressure to the part. The bladder subassembly further includes a bladder cover disposed over the plurality of inner bladders within the tool chamber to provide a barrier between the plurality of inner bladders and the part.
    Type: Grant
    Filed: January 16, 2020
    Date of Patent: January 24, 2023
    Assignee: The Boeing Company
    Inventors: Adam David Knebel, Justin Joseph Schell, Mark A. Monzyk, Randall D. Wilkerson, Amol Ogale
  • Patent number: 11214020
    Abstract: This disclosure is directed to a thermoplastic composite material forming method and tooling used to perform the method. More specifically, this disclosure is directed to a method of fabricating large, complex thermoplastic composite part shapes with a consolidation tool having a conformable tooling bladder that heat thermoplastic material in the tool and provide thermoplastic material consolidation pressure in directions in the tool to form a part shape of thermoplastic composite material. A novel tooling concept is used to fabricate large, complex thermoplastic composite part shapes which are not easily producible using traditional methods.
    Type: Grant
    Filed: August 27, 2019
    Date of Patent: January 4, 2022
    Assignee: The Boeing Company
    Inventors: Mike P. Matlack, Alexander M. Rubin, Randall D. Wilkerson, Amol Ogale
  • Publication number: 20210221073
    Abstract: A tool for forming a part includes a first tool portion including a first tool surface. The tool further includes a second tool portion comprising a second tool surface facing the first tool surface, wherein the first tool surface and the second tool surface define a tool chamber for forming the part. The tool further includes a bladder subassembly disposed in the tool chamber between the first tool surface and the second tool surface. The bladder subassembly includes a plurality of inner bladders disposed within tool chamber, wherein each inner bladder of the plurality of inner bladders includes an inner bladder chamber that is independently inflatable to selectively apply pressure to the part. The bladder subassembly further includes a bladder cover disposed over the plurality of inner bladders within the tool chamber to provide a barrier between the plurality of inner bladders and the part.
    Type: Application
    Filed: January 16, 2020
    Publication date: July 22, 2021
    Inventors: Adam David Knebel, Justin Joseph Schell, Mark A. Monzyk, Randall D. Wilkerson, Amol Ogale
  • Publication number: 20210205936
    Abstract: Methods and apparatus for semi-automated tack welding of plies of a thermoplastic composite layup are described. An example welding tool includes a stabilization foot, a housing, a compaction foot, and a welder. The stabilization foot has a stabilization surface. The housing has a central axis. The housing is movable relative to the stabilization surface along the central axis of the housing. The compaction foot has a central axis and a compaction surface. The compaction surface is movable relative to the stabilization surface and to the housing along the central axis of the compaction surface. The welder has a central axis and a welding surface. The welding surface is movable relative to the stabilization surface, to the housing, and to the compaction surface along the central axis of the welder.
    Type: Application
    Filed: January 7, 2020
    Publication date: July 8, 2021
    Inventors: Daniel D. Bloch, Roger A. Burgess, Samuel J. Easley, Eric E. Moyes, Randall D. Wilkerson
  • Patent number: 11052494
    Abstract: Methods and apparatus for semi-automated tack welding of plies of a thermoplastic composite layup are described. An example welding tool includes a stabilization foot, a housing, a compaction foot, and a welder. The stabilization foot has a stabilization surface. The housing has a central axis. The housing is movable relative to the stabilization surface along the central axis of the housing. The compaction foot has a central axis and a compaction surface. The compaction surface is movable relative to the stabilization surface and to the housing along the central axis of the compaction surface. The welder has a central axis and a welding surface. The welding surface is movable relative to the stabilization surface, to the housing, and to the compaction surface along the central axis of the welder.
    Type: Grant
    Filed: January 7, 2020
    Date of Patent: July 6, 2021
    Assignee: THE BOEING COMPANY
    Inventors: Daniel D. Bloch, Roger A. Burgess, Samuel J. Easley, Eric E. Moyes, Randall D. Wilkerson
  • Publication number: 20210060873
    Abstract: This disclosure is directed to a thermoplastic composite material forming method and tooling used to perform the method. More specifically, this disclosure is directed to a method of fabricating large, complex thermoplastic composite part shapes with a consolidation tool having a conformable tooling bladder that heat thermoplastic material in the tool and provide thermoplastic material consolidation pressure in directions in the tool to form a part shape of thermoplastic composite material. A novel tooling concept is used to fabricate large, complex thermoplastic composite part shapes which are not easily producible using traditional methods.
    Type: Application
    Filed: August 27, 2019
    Publication date: March 4, 2021
    Applicant: The Boeing Company
    Inventors: Mike P. Matlack, Alexander M. Rubin, Randall D. Wilkerson, Amol Ogale
  • Patent number: 10821653
    Abstract: An elongate thermoplastic composite member is fabricated by a continuous molding process. A pre-consolidated thermoplastic laminate is softened by heating it to a temperature below its melting layup, and is fed substantially continuously through multiple sets of tool dies. The tool dies incrementally mold portions of softened laminate over a mandrel to form the laminate into a shape having a closed cross section.
    Type: Grant
    Filed: February 24, 2010
    Date of Patent: November 3, 2020
    Inventors: Alexander M. Rubin, James R. Fox, Randall D. Wilkerson
  • Patent number: 10814562
    Abstract: Systems and methods are provided for composite part fabrication. One embodiment is a method that includes placing a laminate onto a base of a mandrel between side walls of the mandrel, placing edge dams between the side walls and the laminate that each abut the laminate and abut one of the side walls, each edge dam having a Coefficient of Thermal Expansion (CTE) greater than a CTE of the mandrel, the CTE of the mandrel being greater than a CTE of the laminate, heating the laminate, edge dams, and mandrel, and during the heating, thermally expanding the edge dams an amount that corresponds with a difference in thermal expansion between the laminate and the mandrel.
    Type: Grant
    Filed: March 21, 2018
    Date of Patent: October 27, 2020
    Assignee: The Boeing Company
    Inventors: Cori Amanda Jackson, Randall D. Wilkerson, Garrett Denard Williams
  • Patent number: 10800110
    Abstract: Multifunction end effector apparatus and methods for assembling thermoplastic composite articles are disclosed. An example apparatus for assembling a thermoplastic composite article includes a robot and an end effector coupled to the robot. The end effector includes a cutting head, a vacuum head, and a welding head.
    Type: Grant
    Filed: April 11, 2017
    Date of Patent: October 13, 2020
    Assignee: THE BOEING COMPANY
    Inventors: Daniel D. Bloch, Randall D. Wilkerson, Camille D. Carter, Zachary L. Green, Nicole R. Williams, Eric Moyes, Gregory J. S. Hickman, Scott E. Martin
  • Patent number: 10786956
    Abstract: Systems and methods are provided for forming composite parts. One embodiment is a method that includes receiving flat unidirectional tape that is continuous and fiber-reinforced, and drawing the tape through a fixed die that heats and plastically deforms the tape into a gap filler having a non-flat cross section.
    Type: Grant
    Filed: April 26, 2017
    Date of Patent: September 29, 2020
    Assignee: The Boeing Company
    Inventors: Randall D. Wilkerson, Donald C. Besselsen, Philip P. Steinacher, Jerry Lee Newland
  • Patent number: 10702993
    Abstract: End effectors having compaction feet for welding thermoplastic parts of thermoplastic composite laminated articles are described. An example end effector is to be coupled to a robot. The end effector includes a welding head. The welding head includes a welder having a first central axis and a compaction foot having a second central axis. The welder is movable along the first central axis between a first retracted position and a first extended position relative to a surface of the end effector. The compaction foot circumscribes the welder and is movable along the second central axis between a second retracted position and a second extended position relative to the surface.
    Type: Grant
    Filed: July 5, 2018
    Date of Patent: July 7, 2020
    Assignee: The Boeing Company
    Inventors: Daniel David Bloch, Zachary Green, John Emil Larson, Eric E. Moyes, Randall D. Wilkerson
  • Publication number: 20200171711
    Abstract: Systems and methods are provided for creating precursors for consolidating composite parts. One embodiment is a method for forming a metallic structure. The method includes forming a precursor for a pressure membrane that includes a contour having a linearized length corresponding with a linearized length of a surface of a forming tool. The method also includes affixing a perimeter of the precursor to a perimeter of a base member, leaving a volume between the base member and the precursor, altering a shape of the precursor at a superplastic temperature by forcing the precursor into complementary contact with the surface of the forming tool, and setting the shape of the precursor while the precursor is held in complementary contact.
    Type: Application
    Filed: November 29, 2018
    Publication date: June 4, 2020
    Inventors: Marc R. Matsen, Lee Charles Firth, Randall D. Wilkerson, Julie F. Murphy, Ravi Verma
  • Publication number: 20200009743
    Abstract: End effectors having compaction feet for welding thermoplastic parts of thermoplastic composite laminated articles are described. An example end effector is to be coupled to a robot. The end effector includes a welding head. The welding head includes a welder having a first central axis and a compaction foot having a second central axis. The welder is movable along the first central axis between a first retracted position and a first extended position relative to a surface of the end effector. The compaction foot circumscribes the welder and is movable along the second central axis between a second retracted position and a second extended position relative to the surface.
    Type: Application
    Filed: July 5, 2018
    Publication date: January 9, 2020
    Inventors: Daniel David Bloch, Zachary Green, John Emil Larson, Eric E. Moyes, Randall D. Wilkerson
  • Publication number: 20190291352
    Abstract: Systems and methods are provided for composite part fabrication. One embodiment is a method that includes placing a laminate onto a base of a mandrel between side walls of the mandrel, placing edge dams between the side walls and the laminate that each abut the laminate and abut one of the side walls, each edge dam having a Coefficient of Thermal Expansion (CTE) greater than a CTE of the mandrel, the CTE of the mandrel being greater than a CTE of the laminate, heating the laminate, edge dams, and mandrel, and during the heating, thermally expanding the edge dams an amount that corresponds with a difference in thermal expansion between the laminate and the mandrel.
    Type: Application
    Filed: March 21, 2018
    Publication date: September 26, 2019
    Inventors: Cori Amanda Jackson, Randall D. Wilkerson, Garrett Denard Williams
  • Patent number: 10414107
    Abstract: Thermoplastic laminates are fabricated in a continuous compression molding production line. A lay-up of laminate plies is placed in a recess on a carrying tool, and the tool is moved through successive forming operations on the line, including preforming and consolidation operations. The tool is separated from the fully formed part at the end of the line and may be reused. Use of the carrying tool reduces material scrap.
    Type: Grant
    Filed: December 4, 2017
    Date of Patent: September 17, 2019
    Assignee: The Boeing Company
    Inventors: Randall D. Wilkerson, James R. Fox, Alexander M. Rubin
  • Patent number: 10232571
    Abstract: A system and method for forming an item from a material, which may include elongated fibers and/or stretched broken fibers. The material is placed on a first clamping portion, which is placed on a fixture. A second clamping portion is placed against the material and the first clamping portion and secured together, forming a clamping assembly. The clamping assembly is removed from the fixture and placed on a first die portion, having a first profile. A second die portion is also provided, having a second profile. In forming the item, at least one of the first die portion and the second die portion are moved toward each other such that a second surface of the first die portion and a first surface of the second die portion contact and form the material into the item generally replicating the first profile and the second profile.
    Type: Grant
    Filed: September 22, 2015
    Date of Patent: March 19, 2019
    Assignee: the boeing company
    Inventors: Mike P. Matlack, Stephen J. Morgan, Thomas K. Tsotsis, James R. Fox, Randall D. Wilkerson
  • Patent number: 10226905
    Abstract: A system and method for forming an item from a material, which may include elongated fibers and/or stretched broken fibers. The material is placed on a first clamping portion, which is placed on a fixture. A second clamping portion is placed against the material and the first clamping portion and secured together, forming a clamping assembly. The clamping assembly is removed from the fixture and placed on a first die portion, having a first profile. A second die portion is also provided, having a second profile. In forming the item, at least one of the first die portion and the second die portion are moved toward each other such that a second surface of the first die portion and a first surface of the second die portion contact and form the material into the item generally replicating the first profile and the second profile.
    Type: Grant
    Filed: September 22, 2015
    Date of Patent: March 12, 2019
    Assignee: the boeing company
    Inventors: Mike P. Matlack, Stephen J. Morgan, Thomas K. Tsotsis, James R. Fox, Randall D. Wilkerson