Patents by Inventor Randall Dow Wilkerson
Randall Dow 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).
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Publication number: 20240123657Abstract: Continuous compression molding machines (CCMMs) and methods of continuous compression molding a consolidated thermoplastic matrix composite material are disclosed herein. The CCMMs include a mold, a heat zone heating structure, a consolidation zone heating structure, and a stress relaxation zone heating structure. The CCMMs also include a press structure, a demold structure, and a supply structure. The methods include providing a thermoplastic matrix composite material (TMCM) that includes a thermoplastic material to a CCMM. During the providing, the methods also include heating the TMCM within a heat zone of the CCMM, cooling and consolidating the TMCM within a consolidation zone of the CCMM, relaxing stress within the TMCM within a stress relaxation zone of the CCMM, demolding the TMCM within a demold zone of the CCMM at a mold temperature that is greater than a glass transition temperature of the thermoplastic material, and periodically compressing the TMCM.Type: ApplicationFiled: December 27, 2023Publication date: April 18, 2024Inventors: Trevor David Charest, Aaron Ross Cowin, Gregory James Schoepen Hickman, Justin Joseph Schell, Randall Dow Wilkerson
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Publication number: 20240100784Abstract: Methods and apparatus for manufacturing a thermoplastic structure include laying a first plurality of braided plies on a mandrel, and laying one or more unidirectional plies on the plurality of braided plies. A second plurality of braided plies is laid on the one or more unidirectional plies. The layup thereby forms a thermoplastic structure having combined braided and unidirectional plies.Type: ApplicationFiled: September 28, 2022Publication date: March 28, 2024Inventors: Amol Ogale, Randall Dow Wilkerson, Alexander Rubin
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Patent number: 11904510Abstract: Continuous compression molding machines (CCMMs) and methods of continuous compression molding a consolidated thermoplastic matrix composite material are disclosed herein. The CCMMs include a mold, a heat zone heating structure, a consolidation zone heating structure, and a stress relaxation zone heating structure. The CCMMs also include a press structure, a demold structure, and a supply structure. The methods include providing a thermoplastic matrix composite material (TMCM) that includes a thermoplastic material to a CCMM. During the providing, the methods also include heating the TMCM within a heat zone of the CCMM, cooling and consolidating the TMCM within a consolidation zone of the CCMM, relaxing stress within the TMCM within a stress relaxation zone of the CCMM, demolding the TMCM within a demold zone of the CCMM at a mold temperature that is greater than a glass transition temperature of the thermoplastic material, and periodically compressing the TMCM.Type: GrantFiled: February 10, 2022Date of Patent: February 20, 2024Assignee: The Boeing CompanyInventors: Trevor David Charest, Aaron Ross Cowin, Gregory James Schoepen Hickman, Justin Joseph Schell, Randall Dow Wilkerson
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Publication number: 20230249384Abstract: Continuous compression molding machines (CCMMs) and methods of continuous compression molding a consolidated thermoplastic matrix composite material are disclosed herein. The CCMMs include a mold, a heat zone heating structure, a consolidation zone heating structure, and a stress relaxation zone heating structure. The CCMMs also include a press structure, a demold structure, and a supply structure. The methods include providing a thermoplastic matrix composite material (TMCM) that includes a thermoplastic material to a CCMM. During the providing, the methods also include heating the TMCM within a heat zone of the CCMM, cooling and consolidating the TMCM within a consolidation zone of the CCMM, relaxing stress within the TMCM within a stress relaxation zone of the CCMM, demolding the TMCM within a demold zone of the CCMM at a mold temperature that is greater than a glass transition temperature of the thermoplastic material, and periodically compressing the TMCM.Type: ApplicationFiled: February 10, 2022Publication date: August 10, 2023Inventors: Trevor David Charest, Aaron Ross Cowin, Gregory James Schoepen Hickman, Justin Joseph Schell, Randall Dow Wilkerson
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Patent number: 11633931Abstract: A method and apparatus for a continuous compression molding machine. The continuous compression molding machine comprises a tooling die, extending through a heating zone and a cooling zone, a tooling sleeve, and a biasing system. The tooling sleeve corresponds to the tooling die and is for use in forming a thermoplastic composite part from a thermoplastic composite charge when the tooling sleeve with the thermoplastic composite charge is moved with respect to the tooling die through the heating zone and the cooling zone. The biasing system is configured to hold the thermoplastic charge at a first angle within the heating zone and hold the thermoplastic composite charge at a second angle within the cooling zone, as the tooling sleeve moves through the heating zone and the cooling zone with the thermoplastic composite charge. The first angle is different from the second angle.Type: GrantFiled: August 13, 2020Date of Patent: April 25, 2023Assignee: The Boeing CompanyInventors: Philip P. Steinacher, Randall Dow Wilkerson, James Rodney Fox, Michael Palmore Matlack, Ryan Joseph Merriman, Donald C. Besselsen, David Phillip Bruk
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Patent number: 11559956Abstract: A method and structure for processing a plurality of prepreg sheets includes a conveyor assembly having a first conveyor, a second conveyor, and a processing zone positioned between the first and second conveyors. In an implementation, a plurality of prepreg sheets are advanced from a plurality of material supply creels into the processing zone by a first conveyor and a second conveyor turning in opposite directions. Within the processing zone, a compressive pressure is applied to the prepreg sheets by first pressure plates attached to first conveyor and second pressure plates attached to the second conveyor. A thermoplastic within the prepreg sheets is melted within the processing zone by a heater to consolidate the prepreg sheets into a consolidated laminate.Type: GrantFiled: October 31, 2019Date of Patent: January 24, 2023Assignee: THE BOEING COMPANYInventors: Paul Gabriel Werntges, Aaron Ross Cowin, Eileen Miller, Randall Dow Wilkerson, Joshua Paul Koehn
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Publication number: 20210129461Abstract: A method and structure for processing a plurality of prepreg sheets includes a conveyor assembly having a first conveyor, a second conveyor, and a processing zone positioned between the first and second conveyors. In an implementation, a plurality of prepreg sheets are advanced from a plurality of material supply creels into the processing zone by a first conveyor and a second conveyor turning in opposite directions. Within the processing zone, a compressive pressure is applied to the prepreg sheets by first pressure plates attached to first conveyor and second pressure plates attached to the second conveyor. A thermoplastic within the prepreg sheets is melted within the processing zone by a heater to consolidate the prepreg sheets into a consolidated laminate.Type: ApplicationFiled: October 31, 2019Publication date: May 6, 2021Applicant: The Boeing CompanyInventors: Paul Gabriel Werntges, Aaron Ross Cowin, Eileen Miller, Randall Dow Wilkerson, Joshua Paul Koehn
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Publication number: 20200368945Abstract: A method and apparatus for a continuous compression molding machine. The continuous compression molding machine comprises a tooling die, extending through a heating zone and a cooling zone, a tooling sleeve, and a biasing system. The tooling sleeve corresponds to the tooling die and is for use in forming a thermoplastic composite part from a thermoplastic composite charge when the tooling sleeve with the thermoplastic composite charge is moved with respect to the tooling die through the heating zone and the cooling zone. The biasing system is configured to hold the thermoplastic charge at a first angle within the heating zone and hold the thermoplastic composite charge at a second angle within the cooling zone, as the tooling sleeve moves through the heating zone and the cooling zone with the thermoplastic composite charge. The first angle is different from the second angle.Type: ApplicationFiled: August 13, 2020Publication date: November 26, 2020Inventors: Philip P. Steinacher, Randall Dow Wilkerson, James Rodney Fox, Michael Palmore Matlack, Ryan Joseph Merriman, Donald C. Besselsen, David Phillip Bruk
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Patent number: 10773430Abstract: A method and apparatus for a continuous compression molding machine. The continuous compression molding machine comprises a tooling die, extending through a heating zone and a cooling zone, a tooling sleeve, and a biasing system. The tooling sleeve corresponds to the tooling die and is for use in forming a thermoplastic composite part from a thermoplastic composite charge when the tooling sleeve with the thermoplastic composite charge is moved with respect to the tooling die through the heating zone and the cooling zone. The biasing system is configured to hold the thermoplastic charge at a first angle within the heating zone and hold the thermoplastic composite charge at a second angle within the cooling zone, as the tooling sleeve moves through the heating zone and the cooling zone with the thermoplastic composite charge. The first angle is different from the second angle.Type: GrantFiled: April 25, 2017Date of Patent: September 15, 2020Assignee: The Boeing CompanyInventors: Philip P. Steinacher, Randall Dow Wilkerson, James Rodney Fox, Michael Palmore Matlack, Ryan Joseph Merriman, Donald C. Besselsen, David Phillip Bruk
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Patent number: 10766207Abstract: A cascade for a jet engine thrust reverser is fabricated by co-consolidating pre-consolidated thermoplastic strongbacks and vanes. The strongbacks are reinforced with continuous fibers, and the vanes are reinforced with discontinuous fibers.Type: GrantFiled: January 16, 2018Date of Patent: September 8, 2020Assignee: The Boeing CompanyInventors: Aaron William Bartel, Robert Darel Morrow, Alan James Scott, Alexandre D. Curaudeau, Tunde Abiodun Olaniyan, Leonard Joseph England, Randall Dow Wilkerson, Robin L. Westberg
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Patent number: 10434726Abstract: Thermoplastic composite parts are produced by automated fiber placement followed by stamp forming a layup having tailored fiber orientations. The tailored fiber orientations are achieved by tow steering and result in a layup that does not wrinkle during forming.Type: GrantFiled: July 13, 2015Date of Patent: October 8, 2019Assignee: The Boeing CompanyInventors: Gregory James Schoepen Hickman, James R. Fox, Charles R. Prebil, Randall Dow Wilkerson
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Patent number: 10232532Abstract: Consolidation tooling is used in a continuous compression molding machine to produce a fiber reinforced thermoplastic part having a varying height. The tooling includes first and second tool dies adapted to compress and form a multi-ply stack of thermoplastic prepreg into a part, and at least a first tooling sleeve movable through the first and second tool dies. The tooling sleeve has at least a first tapered portion engageable with the multi-ply stack.Type: GrantFiled: March 13, 2012Date of Patent: March 19, 2019Assignee: The Boeing CompanyInventors: Charles R. Prebil, James R. Fox, Randall Dow Wilkerson, Sharon Sher Ying Wong
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Patent number: 10207466Abstract: A method and apparatus are used to pre-consolidate and de-bulk a thermoplastic composite ply stack prior to full consolidation and forming to the final part shape. Pre-consolidation and de-bulking is achieved by heating the ply stack to a temperature below the melting point of the thermoplastic in order to soften the plies, and then compress the ply stack.Type: GrantFiled: February 1, 2016Date of Patent: February 19, 2019Assignee: The Boeing CompanyInventors: Randall Dow Wilkerson, James Rodney Fox
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Patent number: 10118350Abstract: Continuous compression molding process and apparatus for fabricating thermoplastic composite parts from pre-formed thermoplastic composite laminates with tooling dies have a staggered bevel feature at an entry side of the tooling dies. Staggering the length of the bevel feature in each section between bends in a surface contour along the width of the incoming edge of the tooling dies prevents excess material from being trapped and forming wrinkles in the finished thermoplastic part. The length of the taper in each section along the width of the tooling dies is aligned with a pulsed advancement distance of the pre-formed part.Type: GrantFiled: April 21, 2016Date of Patent: November 6, 2018Assignee: The Boeing CompanyInventors: Charles Richard Prebil, Randall Dow Wilkerson, Neal Froeschner
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Publication number: 20180304503Abstract: A method and apparatus for a continuous compression molding machine. The continuous compression molding machine comprises a tooling die, extending through a heating zone and a cooling zone, a tooling sleeve, and a biasing system. The tooling sleeve corresponds to the tooling die and is for use in forming a thermoplastic composite part from a thermoplastic composite charge when the tooling sleeve with the thermoplastic composite charge is moved with respect to the tooling die through the heating zone and the cooling zone. The biasing system is configured to hold the thermoplastic charge at a first angle within the heating zone and hold the thermoplastic composite charge at a second angle within the cooling zone, as the tooling sleeve moves through the heating zone and the cooling zone with the thermoplastic composite charge. The first angle is different from the second angle.Type: ApplicationFiled: April 25, 2017Publication date: October 25, 2018Inventors: Philip P. Steinacher, Randall Dow Wilkerson, James Rodney Fox, Michael Palmore Matlack, Ryan Joseph Merriman, Donald C. Besselsen, David Phillip Bruk
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Publication number: 20180236720Abstract: A cascade for a jet engine thrust reverser is fabricated by co-consolidating pre-consolidated thermoplastic strongbacks and vanes. The strongbacks are reinforced with continuous fibers, and the vanes are reinforced with discontinuous fibers.Type: ApplicationFiled: January 16, 2018Publication date: August 23, 2018Inventors: Aaron William Bartel, Robert Darel Morrow, Alan James Scott, Alexandre D. Curaudeau, Tunde Abiodun Olaniyan, Leonard Joseph England, Randall Dow Wilkerson, Robin L. Westberg
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Patent number: 10029398Abstract: A method and apparatus for forming a stiffened thermoplastic panel is presented. The method may comprise placing a number of forming tools within a number of concave areas of a thermoplastic preform. The method may also place the thermoplastic preform with the number of forming tools within the number of concave areas on a thermoplastic lay-up to form a workpiece. The method may also position the workpiece within a tool. The tool may have a number of die liners configured to generate heat in response to a magnetic field. The method may also consolidate the workpiece to form the stiffened thermoplastic panel. Consolidating may comprise applying a magnetic field to the number of die liners to heat the workpiece to a consolidation temperature.Type: GrantFiled: January 27, 2015Date of Patent: July 24, 2018Assignee: THE BOEING COMPANYInventors: Marc Rollo Matsen, Jeffery Lee Marcoe, Gregory James Schoepen Hickman, Alexander M. Rubin, Lee Charles Firth, Randall Dow Wilkerson, James R. Fox, Charles Richard Prebil
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Patent number: 9895840Abstract: A cascade for a jet engine thrust reverser is fabricated by co-consolidating pre-consolidated thermoplastic strongbacks and vanes. The strongbacks are reinforced with continuous fibers, and the vanes are reinforced with discontinuous fibers.Type: GrantFiled: May 15, 2014Date of Patent: February 20, 2018Assignee: THE BOEING COMPANYInventors: Aaron William Bartel, Robert Darel Morrow, Alan James Scott, Alexandre D. Curaudeau, Tunde Abiodun Olaniyan, Leonard Joseph England, Randall Dow Wilkerson, Robin L. Westberg
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Patent number: 9662742Abstract: A method and apparatus is presented. A method may comprise positioning a metallic bladder within a tool, the tool having a number of die liners that generate heat when exposed to a magnetic field; applying the magnetic field to the number of die liners to heat the metallic bladder; and pressurizing the metallic bladder.Type: GrantFiled: July 7, 2014Date of Patent: May 30, 2017Assignee: THE BOEING COMPANYInventors: Marc Rollo Matsen, Alexander M. Rubin, Randall Dow Wilkerson, Carey E. Wilkinson, James Rodney Fox, Charles R. Prebil, Gregory James Schoepen Hickman, Jeffery Lee Marcoe
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Publication number: 20160229094Abstract: Continuous compression molding process and apparatus for fabricating thermoplastic composite parts from pre-formed thermoplastic composite laminates with tooling dies have a staggered bevel feature at an entry side of the tooling dies. Staggering the length of the bevel feature in each section between bends in a surface contour along the width of the incoming edge of the tooling dies prevents excess material from being trapped and forming wrinkles in the finished thermoplastic part. The length of the taper in each section along the width of the tooling dies is aligned with a pulsed advancement distance of the pre-formed part.Type: ApplicationFiled: April 21, 2016Publication date: August 11, 2016Inventors: Charles Richard PREBIL, Randall Dow WILKERSON, Neal FROESCHNER