Patents by Inventor Richard A. Callis
Richard A. Callis 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: 11123899Abstract: Method for seaming a multi-sectional composite tooling for use in molding large composite structures. The tooling includes at least two tooling sections that are made from quasi-isotropic sheet molding compound. The two tooling sections are seamed together with a scarf plug at the tooling surface. The scarf plug is composed of specially oriented layers of consolidated quasi-isotropic sheet molding compound. The scarf plug is made from the same type of quasi-isotropic sheet molding compound that is used to make the tooling sections.Type: GrantFiled: April 17, 2019Date of Patent: September 21, 2021Assignee: HEXCEL CORPORATIONInventors: Mark Gerdisch, Richard Callis, Adam Senta
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Publication number: 20190248046Abstract: Method for seaming a multi-sectional composite tooling for use in molding large composite structures. The tooling includes at least two tooling sections that are made from quasi-isotropic sheet molding compound. The two tooling sections are seamed together with a scarf plug at the tooling surface. The scarf plug is composed of specially oriented layers of consolidated quasi-isotropic sheet molding compound. The scarf plug is made from the same type of quasi-isotropic sheet molding compound that is used to make the tooling sections.Type: ApplicationFiled: April 17, 2019Publication date: August 15, 2019Inventors: Mark Gerdisch, Richard Callis, Adam Senta
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Publication number: 20170036375Abstract: A multi-sectional composite tooling for use in molding large composite structures. The tooling includes at least two tooling sections that are made from quasi-isotropic sheet molding compound. The two tooling sections are seamed together with a scarf plug at the tooling surface. The scarf plug is composed of specially oriented layers of consolidated quasi-isotropic sheet molding compound. The scarf plug is made from the same type of quasi-isotropic sheet molding compound that is used to make the tooling sections.Type: ApplicationFiled: August 7, 2015Publication date: February 9, 2017Inventors: Mark Gerdisch, Richard Callis, Adam Senta
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Patent number: 8510946Abstract: Methods and apparatus are provided for making a rotor blade spar from composite material wherein a multi-component mandrel is used to form the composite spar. The mandrel is made using a number of components that are assembled and held in place using a roller assembly. The roller assembly is removed after pre-cure lay up and compaction of the composite material. Once the roller assembly is removed, the remaining mandrel components can be separated from each other and easily removed from the spar. The mandrel components, including the roller assembly, can then be re-assembled and re-used to form additional composite spars.Type: GrantFiled: October 19, 2011Date of Patent: August 20, 2013Assignee: Hexcel CorporationInventors: Richard A. Callis, Wayne Johnston, Nate Gray, David P. Bailey
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Patent number: 8257631Abstract: Machinable composite molds for use in molding composite structures. The mold includes a mold body having a tool surface that is shaped to provide the molded surface of the composite structure. The mold body is made up of at least one mold layer composed of a quasi-isotropic material composed of a plurality of randomly oriented fiber bundles or chips impregnated with a resin. The use of randomly oriented fiber chips allows post-cure machining of the mold body.Type: GrantFiled: May 30, 2011Date of Patent: September 4, 2012Assignee: Hexcel CorporationInventor: Richard A. Callis
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Patent number: 8163219Abstract: Methods and apparatus are provided for making a rotor blade spar from composite material wherein a multi-component mandrel is used to form the composite spar. The mandrel is made using a number of components, which are assembled to provide a structure that is sufficiently strong to maintain the spar shape during pre-cure lay up, compaction and curing of the composite material. The multiple components used to form the mandrel can be separated from each other and easily removed from the spar either before or after curing of the composite material. The mandrel components can then be re-assembled and re-used to form additional composite spars.Type: GrantFiled: May 26, 2010Date of Patent: April 24, 2012Assignee: Hexcel CorporationInventors: Richard A. Callis, Joe White, Jane White, legal representative, Scott Newkirk
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Publication number: 20120034090Abstract: Methods and apparatus are provided for making a rotor blade spar from composite material wherein a multi-component mandrel is used to form the composite spar. The mandrel is made using a number of components that are assembled and held in place using a roller assembly. The roller assembly is removed after pre-cure lay up and compaction of the composite material. Once the roller assembly is removed, the remaining mandrel components can be separated from each other and easily removed from the spar. The mandrel components, including the roller assembly, can then be re-assembled and re-used to form additional composite spars.Type: ApplicationFiled: October 19, 2011Publication date: February 9, 2012Applicant: Hexcel CorporationInventors: Richard A. Callis, Wayne Johnston, Nate Gray, David P. Bailey
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Patent number: 8066504Abstract: Methods and apparatus are provided for making a rotor blade spar from composite material wherein a multi-component mandrel is used to form the composite spar. The mandrel is made using a number of components that are assembled and held in place using a roller assembly. The roller assembly is removed after pre-cure lay up and compaction of the composite material. Once the roller assembly is removed, the remaining mandrel components can be separated from each other and easily removed from the spar. The mandrel components, including the roller assembly, can then be re-assembled and re-used to form additional composite spars.Type: GrantFiled: January 25, 2008Date of Patent: November 29, 2011Assignee: Hexcel CorporationInventors: Richard A. Callis, Wayne Johnston, Nate Gray, David P. Bailey
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Publication number: 20110227249Abstract: Machinable composite molds for use in molding composite structures. The mold includes a mold body having a tool surface that is shaped to provide the molded surface of the composite structure. The mold body is made up of at least one mold layer composed of a quasi-isotropic material composed of a plurality of randomly oriented fiber bundles or chips impregnated with a resin. The use of randomly oriented fiber chips allows post-cure machining of the mold body.Type: ApplicationFiled: May 30, 2011Publication date: September 22, 2011Applicant: Hexcel CorporationInventor: Richard A. Callis
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Patent number: 7972548Abstract: Method for making, modifying and using machinable composite molds for use in molding composite structures. The mold includes a mold body having a tool surface that is shaped to provide the molded surface of the composite structure. The mold body is made up of at least one mold layer composed of a quasi-isotropic material composed of a plurality of randomly oriented fiber bundles or chips impregnated with a resin. The use of randomly oriented fiber chips allows post-cure machining of the mold body.Type: GrantFiled: March 18, 2010Date of Patent: July 5, 2011Assignee: Hexcel CorporationInventor: Richard A. Callis
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Publication number: 20100232973Abstract: Methods and apparatus are provided for making a rotor blade spar from composite material wherein a multi-component mandrel is used to form the composite spar. The mandrel is made using a number of components, which are assembled to provide a structure that is sufficiently strong to maintain the spar shape during pre-cure lay up, compaction and curing of the composite material. The multiple components used to form the mandrel can be separated from each other and easily removed from the spar either before or after curing of the composite material. The mandrel components can then be re-assembled and re-used to form additional composite spars.Type: ApplicationFiled: May 26, 2010Publication date: September 16, 2010Applicant: Hexcel CorporationInventors: Richard A. Callis, Joe White, Scott Newkirk, Jane White
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Publication number: 20100186878Abstract: Method for making, modifying and using machinable composite molds for use in molding composite structures. The mold includes a mold body having a tool surface that is shaped to provide the molded surface of the composite structure. The mold body is made up of at least one mold layer composed of a quasi-isotropic material composed of a plurality of randomly oriented fiber bundles or chips impregnated with a resin. The use of randomly oriented fiber chips allows post-cure machining of the mold body.Type: ApplicationFiled: March 18, 2010Publication date: July 29, 2010Applicant: Hexcel CorporationInventor: Richard A. Callis
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Patent number: 7749421Abstract: Methods and apparatus are provided for making a rotor blade spar from composite material wherein a multi-component mandrel is used to form the composite spar. The mandrel is made using a number of components, which are assembled to provide a structure that is sufficiently strong to maintain the spar shape during pre-cure lay up, compaction and curing of the composite material. The multiple components used to form the mandrel can be separated from each other and easily removed from the spar either before or after curing of the composite material. The mandrel components can then be re-assembled and re-used to form additional composite spars.Type: GrantFiled: December 27, 2006Date of Patent: July 6, 2010Assignee: Hexcel CorporationInventors: Richard A. Callis, Joe White, Jane White, legal representative, Scott Newkirk
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Patent number: 7695661Abstract: Method for making, modifying and using machinable composite molds for use in molding composite structures. The mold includes a mold body having a tool surface that is shaped to provide the molded surface of the composite structure. The mold body is made up of at least one mold layer composed of a quasi-isotropic material composed of a plurality of randomly oriented fiber bundles or chips impregnated with a resin. The use of randomly oriented fiber chips allows post-cure machining of the mold body.Type: GrantFiled: March 9, 2009Date of Patent: April 13, 2010Assignee: Hexcel CorporationInventor: Richard A. Callis
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Publication number: 20090189325Abstract: Methods and apparatus are provided for making a rotor blade spar from composite material wherein a multi-component mandrel is used to form the composite spar. The mandrel is made using a number of components that are assembled and held in place using a roller assembly. The roller assembly is removed after pre-cure lay up and compaction of the composite material. Once the roller assembly is removed, the remaining mandrel components can be separated from each other and easily removed from the spar. The mandrel components, including the roller assembly, can then be re-assembled and re-used to form additional composite spars.Type: ApplicationFiled: January 25, 2008Publication date: July 30, 2009Applicant: Hexcel CorporationInventors: Richard A. Callis, Wayne Johnston, Nate Gray, David P. Bailey
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Publication number: 20090165931Abstract: Method for making, modifying and using machinable composite molds for use in molding composite structures. The mold includes a mold body having a tool surface that is shaped to provide the molded surface of the composite structure. The mold body is made up of at least one mold layer composed of a quasi-isotropic material composed of a plurality of randomly oriented fiber bundles or chips impregnated with a resin. The use of randomly oriented fiber chips allows post-cure machining of the mold body.Type: ApplicationFiled: March 9, 2009Publication date: July 2, 2009Applicant: Hexcel CorporationInventor: Richard A. Callis
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Patent number: 7510390Abstract: Machinable composite molds for use in making a composite structure. The mold includes a mold body having a tool surface that is shaped to provide the molded surface of the composite structure. The mold body is made up of at least one mold layer composed of a quasi-isotropic material composed of a plurality of randomly oriented fiber bundles or chips impregnated with a resin. The use of randomly oriented fiber chips allows post-cure machining of the mold body.Type: GrantFiled: July 13, 2005Date of Patent: March 31, 2009Assignee: Hexcel CorporationInventor: Richard A. Callis
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Publication number: 20080157429Abstract: Methods and apparatus are provided for making a rotor blade spar from composite material wherein a multi-component mandrel is used to form the composite spar. The mandrel is made using a number of components, which are assembled to provide a structure that is sufficiently strong to maintain the spar shape during pre-cure lay up, compaction and curing of the composite material. The multiple components used to form the mandrel can be separated from each other and easily removed from the spar either before or after curing of the composite material. The mandrel components can then be re-assembled and re-used to form additional composite spars.Type: ApplicationFiled: December 27, 2006Publication date: July 3, 2008Applicant: Hexcel CorporationInventors: Richard A. Callis, Joe White, Scott Newkirk, Jane White
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Publication number: 20070012858Abstract: Machinable composite molds for use in making a composite structure. The mold includes a mold body having a tool surface that is shaped to provide the molded surface of the composite structure. The mold body is made up of at least one mold layer composed of a quasi-isotropic material composed of a plurality of randomly oriented fiber bundles or chips impregnated with a resin. The use of randomly oriented fiber chips allows post-cure machining of the mold body.Type: ApplicationFiled: July 13, 2005Publication date: January 18, 2007Inventor: Richard Callis
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Patent number: 4842670Abstract: Methods are disclosed for forming silicone rubber vacuum bag assemblies which can be used repeatedly to debulk and autoclave composite layups. These bags can be formed of a single layup of uncured silicone rubber over a tool of a simple shape or as a layup of uncured silicone rubber over the totality of the tool and a prepreg consisting of a fiber in uncured silicone rubber laid up over areas which do not include male and female radii on the tool. Additionally, a further bag can be constructed by removing those portions of a simple bag which overlay recesses and female radii followed by curing of the silicone rubber and filling of the recesses within uncured silicone rubber followed by a second cure period. Each of the vacuum bag assemblies of the invention is postcured preferredly removed from its defining tool so as to stabilize and fully shrink the silicone rubber. The vacuum bag assemblies are mounted in a silicone rubber membrane which is preferably then supported in a frame.Type: GrantFiled: August 25, 1988Date of Patent: June 27, 1989Assignee: Northrop CorporationInventors: Richard A. Callis, Darryl G. James