Patents by Inventor Sergio H. Sanchez
Sergio H. Sanchez 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: 11248337Abstract: A textile product and a method of manufacturing a composite object therefrom includes interacting a granular material with a textile material, with the textile material impregnated with the elements of the granular material forming a textile product, and introducing the textile product into a molding process so as to form the composite object therefrom. The granular material includes elements including a matrix material having a plurality of reinforcing fibers received therein, the elements of the granular material having a melt viscosity of between about 5 and about 15 grams per 10 minutes and a particle size distribution with a range in particle size of between about 50 and about 595 micrometers.Type: GrantFiled: February 27, 2017Date of Patent: February 15, 2022Assignee: The Boeing CompanyInventors: Brett I. Lyons, Sergio H. Sanchez
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Patent number: 11235508Abstract: A thermoforming system and related methods for manufacturing thermoplastic parts, such as interior panels for aircraft, may include a roll-to-roll operation and a forming press having at least one selectively rotatable tool. The rotatable tool, which may include a mold and/or a die, may be multifaceted, such that different faces of the tool have different mold arrangements for different forming characteristics.Type: GrantFiled: March 2, 2020Date of Patent: February 1, 2022Assignee: The Boeing CompanyInventors: Karen L. Hills, Sergio H. Sanchez, Douglas Alan Brown, Jason Christopher Lail, Michael John Cloud, Jason Turner, Richard V. Phillips, Robert Cook, Hun Sok Basom, DeWayne F. Wendt
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Patent number: 10919188Abstract: An aged granular material and a method of manufacturing an object from the granular material include introducing a granular material into a molding process so as to form the object therefrom. The granular material includes elements including a matrix material having a plurality of reinforcing fibers received therein, the elements of the granular material having a melt viscosity of between about 5 and about 15 grams per 10 minutes and a particle size distribution with a range in particle size of between about 50 and about 595 micrometers.Type: GrantFiled: February 27, 2017Date of Patent: February 16, 2021Assignee: The Boeing CompanyInventors: Brett I. Lyons, Christopher J. Robinson, Sergio H. Sanchez
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Publication number: 20200198218Abstract: A thermoforming system and related methods for manufacturing thermoplastic parts, such as interior panels for aircraft, may include a roll-to-roll operation and a forming press having at least one selectively rotatable tool. The rotatable tool, which may include a mold and/or a die, may be multifaceted, such that different faces of the tool have different mold arrangements for different forming characteristics.Type: ApplicationFiled: March 2, 2020Publication date: June 25, 2020Applicant: The Boeing CompanyInventors: Karen L. Hills, Sergio H. Sanchez, Douglas Alan Brown, Jason Christopher Lail, Michael John Cloud, Jason Turner, Richard V. Phillips, Robert Cook, Hun Sok Basom, DeWayne F. Wendt
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Patent number: 10576680Abstract: A thermoforming system and related methods for manufacturing thermoplastic parts, such as interior panels for aircraft, may include a roll-to-roll operation and a forming press having at least one selectively rotatable tool. The rotatable tool, which may include a mold and/or a die, may be multifaceted, such that different faces of the tool have different mold arrangements for different forming characteristics.Type: GrantFiled: November 19, 2015Date of Patent: March 3, 2020Assignee: The Boeing CompanyInventors: Karen L. Hills, Sergio H. Sanchez, Douglas Alan Brown, Jason Christopher Lail, Michael John Cloud, Jason Turner, Richard V. Phillips, Robert Cook, Hun Sok Basom, DeWayne F. Wendt
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Patent number: 10076895Abstract: A multifunctional fully integral panel system design, a unique material configuration, and a process for fabricating a net shape (or nearly net shape) panel in one production cycle. The panel may comprise a base facing with an outer perimeter, a decorative film applied to the exterior of the base facing, an aft facing having an outer perimeter fused to the base facing, and a reinforcement core disposed between the unfused portions of the base and aft facings, which reinforcement core also acts as acoustic insulation (i.e., a noise attenuator). Alternatively or additionally, a foam core or blanket having thermal and/or acoustic insulation properties is attached to the external surface of the aft facing. The fabrication process involves the application of different heat treatments to panel components having different forming temperature or rubbery/elastic plateaus.Type: GrantFiled: March 4, 2015Date of Patent: September 18, 2018Assignee: The Boeing CompanyInventors: Jayant Dahyabhai Patel, John N. Harris, Sergio H. Sanchez, James A. Fullerton
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Publication number: 20180245281Abstract: A textile product and a method of manufacturing a composite object therefrom includes interacting a granular material with a textile material, with the textile material impregnated with the elements of the granular material forming a textile product, and introducing the textile product into a molding process so as to form the composite object therefrom. The granular material includes elements including a matrix material having a plurality of reinforcing fibers received therein, the elements of the granular material having a melt viscosity of between about 5 and about 15 grams per 10 minutes and a particle size distribution with a range in particle size of between about 50 and about 595 micrometers.Type: ApplicationFiled: February 27, 2017Publication date: August 30, 2018Inventors: Brett I. Lyons, Sergio H. Sanchez
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Publication number: 20180243950Abstract: An aged granular material and a method of manufacturing an object from the granular material include introducing a granular material into a molding process so as to form the object therefrom. The granular material includes elements including a matrix material having a plurality of reinforcing fibers received therein, the elements of the granular material having a melt viscosity of between about 5 and about 15 grams per 10 minutes and a particle size distribution with a range in particle size of between about 50 and about 595 micrometers.Type: ApplicationFiled: February 27, 2017Publication date: August 30, 2018Inventors: Brett I. Lyons, Christopher J. Robinson, Sergio H. Sanchez
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Patent number: 9801276Abstract: A system and method according to one or more embodiments are provided to integrate circuits and/or circuit elements within a structure to form an electronically and/or physically integrated composite structure. For example, a circuit formed on a planar polymer substrate may be conformed to and electrically coupled to a forming structure in a single fabrication step. In one example, a forming structure formed and/or fabricated using an additive manufacturing process includes a contoured surface. A circuit is formed on a planar polymer substrate. The polymer substrate is deformed by environmental stress to substantially conform to the contoured surface of the forming structure and physically and/or electrically couple the circuit on the polymer substrate to a circuit formed on the forming structure. Additional systems and methods are also provided.Type: GrantFiled: November 25, 2015Date of Patent: October 24, 2017Assignee: The Boeing CompanyInventors: Scott R. Johnston, Sergio H. Sanchez
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Publication number: 20170144361Abstract: A thermoforming system and related methods for manufacturing thermoplastic parts, such as interior panels for aircraft, may include a roll-to-roll operation and a forming press having at least one selectively rotatable tool. The rotatable tool, which may include a mold and/or a die, may be multifaceted, such that different faces of the tool have different mold arrangements for different forming characteristics.Type: ApplicationFiled: November 19, 2015Publication date: May 25, 2017Applicant: The Boeing CompanyInventors: Karen L. Hills, Sergio H. Sanchez, Douglas Alan Brown, Jason Christopher Lail, Michael John Cloud, Jason Turner, Richard V. Phillips, Robert Cook, Hun Sok Basom, DeWayne F. Wendt
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Publication number: 20170150602Abstract: A system and method according to one or more embodiments are provided to integrate circuits and/or circuit elements within a structure to form an electronically and/or physically integrated composite structure. For example, a circuit formed on a planar polymer substrate may be conformed to and electrically coupled to a forming structure in a single fabrication step. In one example, a forming structure formed and/or fabricated using an additive manufacturing process includes a contoured surface. A circuit is formed on a planar polymer substrate. The polymer substrate is deformed by environmental stress to substantially conform to the contoured surface of the forming structure and physically and/or electrically couple the circuit on the polymer substrate to a circuit formed on the forming structure. Additional systems and methods are also provided.Type: ApplicationFiled: November 25, 2015Publication date: May 25, 2017Inventors: Scott R. Johnston, Sergio H. Sanchez
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Publication number: 20150174874Abstract: A multifunctional fully integral panel system design, a unique material configuration, and a process for fabricating a net shape (or nearly net shape) panel in one production cycle. The panel may comprise a base facing with an outer perimeter, a decorative film applied to the exterior of the base facing, an aft facing having an outer perimeter fused to the base facing, and a reinforcement core disposed between the unfused portions of the base and aft facings, which reinforcement core also acts as acoustic insulation (i.e., a noise attenuator). Alternatively or additionally, a foam core or blanket having thermal and/or acoustic insulation properties is attached to the external surface of the aft facing. The fabrication process involves the application of different heat treatments to panel components having different forming temperature or rubbery/elastic plateaus.Type: ApplicationFiled: March 4, 2015Publication date: June 25, 2015Applicant: THE BOEING COMPANYInventors: Jayant Dahyabhai Patel, John N. Harris, Sergio H. Sanchez, James A. Fullerton
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Patent number: 9005730Abstract: A multifunctional fully integral panel system design, a unique material configuration, and a process for fabricating a net shape (or nearly net shape) panel in one production cycle. The panel may comprise a base facing with an outer perimeter, a decorative film applied to the exterior of the base facing, an aft facing having an outer perimeter fused to the base facing, and a reinforcement core disposed between the unfused portions of the base and aft facings, which reinforcement core also acts as acoustic insulation (i.e., a noise attenuator). Alternatively or additionally, a foam core or blanket having thermal and/or acoustic insulation properties is attached to the external surface of the aft facing. The fabrication process involves the application of different heat treatments to panel components having different forming temperature or rubbery/elastic plateaus.Type: GrantFiled: November 14, 2011Date of Patent: April 14, 2015Assignee: The Boeing CompanyInventors: Jayant Dahyabhai Patel, John N. Harris, Sergio H. Sanchez, James A. Fullerton
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Publication number: 20130122244Abstract: A multifunctional fully integral panel system design, a unique material configuration, and a process for fabricating a net shape (or nearly net shape) panel in one production cycle. The panel may comprise a base facing with an outer perimeter, a decorative film applied to the exterior of the base facing, an aft facing having an outer perimeter fused to the base facing, and a reinforcement core disposed between the unfused portions of the base and aft facings, which reinforcement core also acts as acoustic insulation (i.e., a noise attenuator). Alternatively or additionally, a foam core or blanket having thermal and/or acoustic insulation properties is attached to the external surface of the aft facing. The fabrication process involves the application of different heat treatments to panel components having different forming temperature or rubbery/elastic plateaus.Type: ApplicationFiled: November 14, 2011Publication date: May 16, 2013Applicant: THE BOEING COMPANYInventors: Jayant Dahyabhai Patel, John N. Harris, Sergio H. Sanchez, James A. Fullerton