Patents by Inventor Robert Blackburn
Robert Blackburn 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: 11745439Abstract: A flexible, self-supporting hybrid veil that is permeable to liquid and gas. The hybrid veil includes: (a) intermingled, randomly arranged fibres in the form of a nonwoven structure; (b) particles dispersed throughout the nonwoven structure, wherein a majority of the particles are penetrating through the thickness of the nonwoven structure; and (c) a polymeric or resinous binder present throughout the veil. Such hybrid veil can be incorporated into composite laminates, prepregs, fabrics and fibrous preforms.Type: GrantFiled: November 11, 2016Date of Patent: September 5, 2023Assignee: CYTEC INDUSTRIES INC.Inventors: Carmelo Luca Restuccia, Robert Blackburn
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Publication number: 20220410435Abstract: Disclosed herein are devices and methods for manufacturing uncured, near-net shape plies. Such devices include: a plurality of spools, each dispensing a dry tow; optionally, a plurality of spreaders to spread the dry tows; optionally, a means to combine the dry tows into a plurality of tapes or bundles; a plurality of feeders, each carrying a tow, tape or bundle, and adapted to maintain the tows, tapes or bundles in a parallel arrangement; a cutting apparatus adapted to independently cut each individual tow, tape or bundle to a pre-determined length; optionally, a conveyor adapted to transport the cut tows, tapes or bundles away from the cutting apparatus; an in-line resin infuser adapted to impregnate the dry tows, tapes or bundles with resin material; and a receiver for the cut tows, tapes or bundles, wherein the cut tows, tapes or bundles are impregnated and configured in the form of a near-net shape ply.Type: ApplicationFiled: November 19, 2020Publication date: December 29, 2022Applicant: Cytec Industries Inc.Inventors: Gary Poynton, Robert Blackburn
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Patent number: 11491748Abstract: A deformable, coated radius filler composed of a continuous or elongated fibrous structure and a tacky, resin surface coating formed by pulling a dry, continuous or elongated fibrous structure through a heated resin bath. The coated radius filler has an inner portion that is substantially free of resin and the resin surface coating has a substantially uniform thickness.Type: GrantFiled: March 14, 2019Date of Patent: November 8, 2022Assignee: CYTEC TECHNOLOGY CORP.Inventors: Dominique Ponsolle, Scott Alfred Rogers, Robert Blackburn, Jonathan Meegan
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Publication number: 20220347940Abstract: A flexible, self-supporting hybrid veil that is permeable to liquid and gas. The hybrid veil includes: (a) intermingled, randomly arranged fibres in the form of a nonwoven structure; (b) particles dispersed throughout the nonwoven structure, wherein a majority of the particles are penetrating through the thickness of the nonwoven structure; and (c) a polymeric or resinous binder present throughout the veil. Such hybrid veil can be incorporated into composite laminates, prepregs, fabrics and fibrous preforms.Type: ApplicationFiled: March 8, 2022Publication date: November 3, 2022Inventors: Carmelo Luca RESTUCCIA, Robert BLACKBURN
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Patent number: 10836118Abstract: A manufacturing process, which includes: (i) preparing a preform; (ii) laying the preform within a mold; (iii) heating the mold to a predetermined temperature; and (iv) injecting a modified resin system, wherein the modified resin system is formulated to have a viscosity below a threshold viscosity at a specific temperature and a high level of toughness. In one embodiment, the modified resin system contains a combination of epoxies, a curing agent, core-shell rubber particles, a thermoplastic material in an amount of less than 7% by weight, wherein in a cured condition, the thermoplastic material is separated into aggregate domains from the base resin, each aggregate domain having an island-like morphology.Type: GrantFiled: July 18, 2017Date of Patent: November 17, 2020Assignee: Cytec Industries Inc.Inventors: Jonathan Edward Meegan, Robert Blackburn
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Patent number: 10683592Abstract: A hybrid, woven textile material that can be used in the manufacturing of fiber-reinforced composite materials. The hybrid textile material is a woven fabric composed of unidirectional fibers interlaced with strips of non-woven fibers in a weaving pattern. In an embodiment, the hybrid textile material is porous or permeable with respect to liquid resins used in Resin Transfer Molding (RTM) processes and a preform formed from this textile material can be infused with liquid resins during such RTM processes.Type: GrantFiled: August 12, 2015Date of Patent: June 16, 2020Assignee: Cytec Industries Inc.Inventors: Robert Blackburn, Samuel Jestyn Hill
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Patent number: 10583615Abstract: A dry, fibrous tape for use in an automated placement process such as ATL or AFP and a preform produced therefrom. The preform is configured for resin infusion. The tape contains a layer of unidirectional fibers, at least one nonwoven veil bonded to one side of the fiber layer, and at least binding materials present within the tape. The preform produced from laying down such tape exhibits a low-bulk property that is close to the final thickness of the cured fiber-reinforced resin article and no further consolidation or compaction is required.Type: GrantFiled: June 25, 2015Date of Patent: March 10, 2020Assignee: Cytec Industries Inc.Inventors: Robert Blackburn, Samuel Jestyn Hill, Dominique Ponsolle, Carmelo Luca Restuccia
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Patent number: 10369773Abstract: Disclosed herein is a dry, self-supporting fibrous material, the fibers of which have been treated with a binder composition. The fibrous material can be slit into tapes or tows that are suitable for use in an Automated Tape Laying (ATL) or Automated Fiber Placement (AFP) process. This fibrous material is suitable for forming preforms which are configured to receive a matrix resin by resin infusion in the manufacturing of structural composite parts.Type: GrantFiled: November 20, 2017Date of Patent: August 6, 2019Assignee: CYTEC INDUSTRIES INC.Inventors: Dominique Ponsolle, Carmelo Luca Restuccia, William Jacobs, Robert Blackburn, Carmelo LoFaro, Richard Price, Marc Doyle, Mitchell Smith, Abdel Abusafieh
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Publication number: 20190210307Abstract: A deformable, coated radius filler composed of a continuous or elongated fibrous structure and a tacky, resin surface coating formed by pulling a dry, continuous or elongated fibrous structure through a heated resin bath. The coated radius filler has an inner portion that is substantially free of resin and the resin surface coating has a substantially uniform thickness.Type: ApplicationFiled: March 14, 2019Publication date: July 11, 2019Applicant: CYTEC TECHNOLOGY CORP.Inventors: Dominique Ponsolle, Scott Alfred Rogers, Robert Blackburn, Jonathan Meegan
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Patent number: 10272621Abstract: A deformable, coated radius filler composed of a continuous or elongated fibrous structure and a tacky, resin surface coating formed by pulling a dry, continuous or elongated fibrous structure through a heated resin bath. The coated radius filler has an inner portion that is substantially free of resin and the resin surface coating has a substantially uniform thickness.Type: GrantFiled: April 24, 2012Date of Patent: April 30, 2019Assignee: CYTEC TECHNOLOGY CORP.Inventors: Dominique Ponsolle, Scott Alfred Rogers, Robert Blackburn, Jonathan Meegan
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Publication number: 20180311912Abstract: A flexible, self-supporting hybrid veil that is permeable to liquid and gas. The hybrid veil includes: (a) intermingled, randomly arranged fibres in the form of a nonwoven structure; (b) particles dispersed throughout the nonwoven structure, wherein a majority of the particles are penetrating through the thickness of the nonwoven structure; and (c) a polymeric or resinous binder present throughout the veil. Such hybrid veil can be incorporated into composite laminates, prepregs, fabrics and fibrous preforms.Type: ApplicationFiled: November 11, 2016Publication date: November 1, 2018Inventors: Carmelo Luca RESTUCCIA, Robert BLACKBURN
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Patent number: 10112375Abstract: Disclosed herein is a dry, self-supporting fibrous material, the fibers of which have been treated with a binder composition. The fibrous material can be slit into tapes or tows that are suitable for use in an Automated Tape Laying (ATL) or Automated Fiber Placement (AFP) process. This fibrous material is suitable for forming preforms which are configured to receive a matrix resin by resin infusion in the manufacturing of structural composite parts.Type: GrantFiled: June 20, 2016Date of Patent: October 30, 2018Assignee: Cytec Industries Inc.Inventors: Dominique Ponsolle, Carmelo Luca Restuccia, William Jacobs, Robert Blackburn, Carmelo LoFaro, Richard Price, Marc Doyle, Mitchell Smith, Abdel Abusafieh
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Publication number: 20180072037Abstract: Disclosed herein is a dry, self-supporting fibrous material, the fibers of which have been treated with a binder composition. The fibrous material can be slit into tapes or tows that are suitable for use in an Automated Tape Laying (ATL) or Automated Fiber Placement (AFP) process. This fibrous material is suitable for forming preforms which are configured to receive a matrix resin by resin infusion in the manufacturing of structural composite parts.Type: ApplicationFiled: November 20, 2017Publication date: March 15, 2018Applicant: CYTEC INDUSTRIES INC.Inventors: Dominique Ponsolle, Carmelo Luca Restuccia, William Jacobs, Robert Blackburn, Carmelo LoFaro, Richard Price, Marc Doyle, Mitchell Smith, Abdel Abusafieh
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Patent number: 9902118Abstract: Embodiments of the invention are directed to resin-soluble thermoplastic veils for use in liquid resin infusion processes, methods of manufacturing resin-soluble thermoplastic veils for use in liquid resin infusion processes, and methods of manufacturing composite articles using resin-soluble thermoplastic veils for use in liquid resin infusion applications. The resin-soluble thermoplastic veils according to embodiments of the invention and of which function as a toughening agent in composites having the veil incorporated therein have improved characteristics including, but not limited to, increased uniformity and decreased thickness relative to prior art veils. These characteristics translate into improvements in the processing of a composite article including, but not limited to, a substantial or complete elimination in premature dissolution of the veil during cure.Type: GrantFiled: December 10, 2014Date of Patent: February 27, 2018Assignee: CYTEC TECHNOLOGY CORP.Inventors: Dominique Ponsolle, Robert Blackburn, Billy Harmon, Richard Price, Marc Doyle
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Publication number: 20170326819Abstract: A manufacturing process, which includes: (i) preparing a preform; (ii) laying the preform within a mold; (iii) heating the mold to a predetermined temperature; and (iv) injecting a modified resin system, wherein the modified resin system is formulated to have a viscosity below a threshold viscosity at a specific temperature and a high level of toughness. In one embodiment, the modified resin system contains a combination of epoxies, a curing agent, core-shell rubber particles, a thermoplastic material in an amount of less than 7% by weight, wherein in a cured condition, the thermoplastic material is separated into aggregate domains from the base resin, each aggregate domain having an island-like morphology.Type: ApplicationFiled: July 18, 2017Publication date: November 16, 2017Applicant: Cytec Technology Corp.Inventors: Jonathan Edward Meegan, Robert Blackburn
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Publication number: 20160303842Abstract: Disclosed herein is a dry, self-supporting fibrous material, the fibers of which have been treated with a binder composition. The fibrous material can be slit into tapes or tows that are suitable for use in an Automated Tape Laying (ATL) or Automated Fiber Placement (AFP) process. This fibrous material is suitable for forming preforms which are configured to receive a matrix resin by resin infusion in the manufacturing of structural composite parts.Type: ApplicationFiled: June 20, 2016Publication date: October 20, 2016Applicant: Cytec Industries Inc.Inventors: Dominique Ponsolle, Carmelo Luca Restuccia, William Jacobs, Robert Blackburn, Carmelo LoFaro, Richard Price, Marc Doyle, Mitchell Smith, Abdel Abusafieh
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Patent number: 9393758Abstract: Disclosed herein is a dry, self-supporting fibrous material, the fibers of which have been treated with a binder composition. The fibrous material can be slit into tapes or tows that are suitable for use in an Automated Tape Laying (ATL) or Automated Fiber Placement (AFP) process. This fibrous material is suitable for forming preforms which are configured to receive a matrix resin by resin infusion in the manufacturing of structural composite parts.Type: GrantFiled: December 19, 2012Date of Patent: July 19, 2016Assignee: Cytec Industries Inc.Inventors: Dominique Ponsolle, Carmelo Luca Restuccia, William Jacobs, Robert Blackburn, Carmelo LoFaro, Richard Price, Marc Doyle, Mitchell Smith, Mark Roman, Abdel Abusafieh
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Publication number: 20160047073Abstract: A hybrid, woven textile material that can be used in the manufacturing of fiber-reinforced composite materials. The hybrid textile material is a woven fabric composed of unidirectional fibers interlaced with strips of non-woven fibers in a weaving pattern. In an embodiment, the hybrid textile material is porous or permeable with respect to liquid resins used in Resin Transfer Molding (RTM) processes and a preform formed from this textile material can be infused with liquid resins during such RTM processes.Type: ApplicationFiled: August 12, 2015Publication date: February 18, 2016Applicant: Cytec Industries Inc.Inventors: Robert Blackburn, Samuel Jestyn Hill
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Patent number: 9259859Abstract: A method for shaping dry preform material prior to resin infusion is disclosed. The starting material to be shaped is a preform blank (e.g. flat sheet) of dry, fibrous material. The shaping process is a vacuum forming process that relies on controlling the vacuum pressure and deformation speed to produce a shaped preform with three-dimensional configuration. The purpose of the shaping process described herein is to enable an automated process to replace the conventional hand lay-up operation.Type: GrantFiled: December 19, 2013Date of Patent: February 16, 2016Assignee: Cytec Industries Inc.Inventors: Robert Blackburn, James Eastbury, Samuel Hill
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Publication number: 20150375461Abstract: A dry, fibrous tape for use in an automated placement process such as ATL or AFP and a preform produced therefrom. The preform is configured for resin infusion. The tape contains a layer of unidirectional fibers, at least one nonwoven veil bonded to one side of the fiber layer, and at least binding materials present within the tape. The preform produced from laying down such tape exhibits a low-bulk property that is close to the final thickness of the cured fiber-reinforced resin article and no further consolidation or compaction is required.Type: ApplicationFiled: June 25, 2015Publication date: December 31, 2015Applicant: Cytec Industries Inc.Inventors: Robert Blackburn, Samuel Jestyn Hill, Dominique Ponsolle, Carmelo Luca Restuccia