Patents by Inventor Steven Robert Hayashi

Steven Robert Hayashi 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: 20190284947
    Abstract: A shroud segment including a forward radial wall, an aft radial wall and at least one interlocking subcomponent. The forward radial wall, an aft radial wall and the at least one interlocking subcomponent are each formed of a ceramic matrix composite (CMC) including reinforcing fibers embedded in a matrix. The shroud segment further including an interlocking mechanical joint joining each of the forward radial wall and the aft radial wall to the at least one interlocking subcomponent. Methods are also provided for joining the forward radial wall and the aft radial wall to the at least one interlocking subcomponent using an interlocking mechanical joint.
    Type: Application
    Filed: March 14, 2018
    Publication date: September 19, 2019
    Inventors: Mackenzie Christopher Hock, Daniel Gene Dunn, Douglas Glenn Decesare, Douglas Melton Carper, Steven Robert Hayashi, Nathan Carl Sizemore, Nolan Leander Cousineau
  • Publication number: 20190275609
    Abstract: A laser machining method includes directing, from an F-theta lens having a long focal length of greater than about 250 millimeters, a laser beam at a non-perpendicular beam tilt angle from an optical axis of the lens having a top-hat profile and a narrow beam divergence angle of between about 1 degree and about 3 degrees towards a workpiece on a stage movable in at least an X-direction and a Y-direction, engaging the directed laser beam with the workpiece disposed in the usable field of view, moving the workpiece and the directed laser beam relative to each other, and removing portions of the workpiece with the directed laser beam to define a machined surface.
    Type: Application
    Filed: May 30, 2019
    Publication date: September 12, 2019
    Inventors: Hongqiang Chen, Steven Robert Hayashi, Xi Zhang
  • Patent number: 10376985
    Abstract: A method for shaping a ceramic matrix composite (CMC) sheet having a first surface and a second surface is presented. The method includes receiving an input signal representative of a predetermined shape and a type of the CMC sheet. Further, the method includes selecting a laser beam based on the received input signal. Also, the method includes projecting the selected laser beam on the CMC sheet to shape the CMC sheet into the predetermined shape.
    Type: Grant
    Filed: December 18, 2015
    Date of Patent: August 13, 2019
    Assignee: GENERAL ELECTRIC COMPANY
    Inventors: Hongqiang Chen, Steven Robert Hayashi, Martin Kin-Fei Lee, Nitin Garg, Nolan Leander Cousineau, Derrick Wayne Knotts
  • Patent number: 10357848
    Abstract: A laser machining method includes directing, from an F-theta lens having a long focal length of greater than about 250 millimeters, a laser beam at a non-perpendicular beam tilt angle from an optical axis of the lens having a top-hat profile and a narrow beam divergence angle of between about 1 degree and about 3 degrees towards a workpiece on a stage movable in at least an X-direction and a Y-direction, engaging the directed laser beam with the workpiece disposed in the usable field of view, moving the workpiece and the directed laser beam relative to each other, and removing portions of the workpiece with the directed laser beam to define a machined surface.
    Type: Grant
    Filed: January 19, 2015
    Date of Patent: July 23, 2019
    Assignee: General Electric Company
    Inventors: Hongqiang Chen, Steven Robert Hayashi, Xi Zhang
  • Patent number: 10222436
    Abstract: A gradient coil comprises a curved conductor, which is tubular and has a general spiral shape. The curved conductor is formed by a process comprising depositing at least one non-conductive material layer by layer to form a substrate, and coating at least a portion of a surface of the substrate with a conductive material. The substrate has a shape matching with the general spiral shape of the curved conductor. Embodiments of the present disclosure further refer to a method for manufacturing the gradient coil.
    Type: Grant
    Filed: August 26, 2016
    Date of Patent: March 5, 2019
    Assignee: GENERAL ELECTRIC COMPANY
    Inventors: Yanzhe Yang, Steven Robert Hayashi, Kevin Warner Flanagan, Prabhjot Singh, Jian Lin, Jean-Baptiste Mathieu, Kenneth Paul Zarnock, Thomas Kwok-Fah Foo
  • Patent number: 10118792
    Abstract: Unwinding systems and methods are provided for unwinding a fiber from a bobbin. The unwinding system can include an axle defining a first axis extending an axial direction, a bobbin rotatably mounted around the axle, a pulley positioned to receive the fiber from the bobbin, wherein the pulley is rotatable around a second axis, and a sensor positioned between the bobbin and the pulley. The bobbin is moveable along the axial direction, and wherein the fiber extends tangentially from a surface of the bobbin.
    Type: Grant
    Filed: August 3, 2016
    Date of Patent: November 6, 2018
    Assignee: General Electric Company
    Inventors: Theodore Robert Grossman, Roger Antonio Aparicio, Martin Peter Gill, Steven Robert Hayashi, Andrew William Miller
  • Publication number: 20180236579
    Abstract: A multi-loop controller component for an electric discharge machining (EDM) system includes a plurality of power loop circuits coupled to an output of a power supply of the EDM system and configured to receive DC electric power from the power supply. Each power loop circuitis electrically-isolated from other power loop circuits. The multi-loop controller component also includes a plurality of transistors. Each transistor is coupled to a respective power loop circuit and is configured to switch between an ON state and an OFF state to generate a pulse of the DC electric power through the respective power loop circuit. In addition, the multi-loop controller component has a drive controller coupled to the plurality of transistors. The drive controller is configured to transmit at least one control signal to at least one of the transistors to facilitate switching the transistor between the ON state and the OFF state.
    Type: Application
    Filed: February 23, 2017
    Publication date: August 23, 2018
    Inventors: Yuanfeng Luo, Yuefeng Luo, Dale Robert Lombardo, Steven Robert Hayashi
  • Publication number: 20180230062
    Abstract: Systems and methods for forming ceramic matrix composite (CMC) components are provided. The CMC component includes a reinforcement material having a plurality of filaments that are at least partially electrically conductive. The plurality of filaments are charged by a charging element with an electric charge of the same sign such that adjacent filaments are in an expanded spatial relationship relative to one another while being coated. While in the expanded spatial relationship, the filaments can also be pulled through a matrix slurry.
    Type: Application
    Filed: February 13, 2017
    Publication date: August 16, 2018
    Inventors: Theodore Robert Grossman, James Scott Vartuli, Steven Robert Hayashi
  • Patent number: 10046382
    Abstract: A method of casting a low alloy steel using a mold is disclosed. The method includes receiving the mold having a foam pattern disposed within a sand casing. The received foam pattern is coated with a permeable refractory coating and is disposed between compacted sand and the sand casing. The method further includes pouring a molten metal comprising a low alloy steel having a carbon content in a range from about 0.1 to about 0.4 percent into the mold so as to vaporize the foam pattern and remove gasification products through the permeable refractory coating, to form a low alloy steel casting. Further, the method includes removing the low alloy steel casting from the mold.
    Type: Grant
    Filed: November 15, 2013
    Date of Patent: August 14, 2018
    Assignee: General Electric Company
    Inventors: Qi Zhao, Steven Robert Hayashi, Brian Victor Moore, Daniel Tribeni Persaud, Michael Douglas Arnett, Junyoung Park
  • Patent number: 10022812
    Abstract: A method of machining a work-piece formed of titanium-based material, using a machining apparatus, is described. The method includes the steps of providing an electrically-conductive electrode contained within a spindle assembly, in a pre-selected distance and position relative to the titanium-based work-piece; while electrically powering the electrode and the work-piece with a power supply. In the process, fluid electrolyte is circulated through at least two pathways in the machining apparatus—an internal conduit within the spindle assembly; and an external conduit. The charged electrode is moved relative to the work-piece in a plunging motion, to remove material from the work-piece at a relatively high rate, using a high-speed electro-erosion (HSEE) process.
    Type: Grant
    Filed: October 9, 2014
    Date of Patent: July 17, 2018
    Assignee: GENERAL ELECTRIC COMPANY
    Inventors: Yuanfeng Luo, Steven Robert Hayashi, Andrew Lee Trimmer, Mark James Cintula
  • Patent number: 9943921
    Abstract: An electrochemical machining system for machining a conductive work piece is provided. The system includes a drilling tool configured to remove material from the conductive work piece. The drilling tool is configured to advance within the conductive work piece along a tool path to form a bore hole having a variable geometry that extends through the conductive work piece when the material is removed therefrom. The system further includes an inspection device configured to determine a position of the drilling tool along the tool path, and a controller configured to communicate with the inspection device. The controller is further configured to compare the tool path to a nominal tool path, and determine a position error of said drilling tool, the position error defined by a difference between the tool path and the nominal tool path.
    Type: Grant
    Filed: July 30, 2015
    Date of Patent: April 17, 2018
    Assignee: GENERAL ELECTRIC COMPANY
    Inventors: Andrew Lee Trimmer, Steven Robert Hayashi, Edward James Nieters, Jeremy Gordon McNamara
  • Publication number: 20180065200
    Abstract: An electrical machining method comprises machining a workpiece by an electrical machining device comprising an electrode; increasing a feedrate of the electrode at a first acceleration if a discharge current passing through the electrode and the workpiece is lower than a discharge current reference; and decreasing the feedrate of the electrode at a second acceleration if the discharge current is higher than the discharge current reference, wherein the second acceleration has an absolute value higher than that of the first acceleration.
    Type: Application
    Filed: July 25, 2017
    Publication date: March 8, 2018
    Inventors: Dong LIU, Andrew Lee TRIMMER, Yuanfeng LUO, Steven Robert HAYASHI
  • Publication number: 20180037512
    Abstract: Methods for coating a fiber are provided. The method can include unwinding a silicon carbide-containing fibrous material from a bobbin rotatably mounted around an axle and forming a boron nitride coating onto the silicon carbide-containing fibrous material. The bobbin is moved along the axial direction such that the silicon carbide-containing fibrous material defines an unwind angle with the axial direction, with the unwind angle being maintained between about 80° to about 100°.
    Type: Application
    Filed: August 3, 2016
    Publication date: February 8, 2018
    Inventors: Theodore Robert Grossman, Roger Antonio Aparicio, Martin Peter Gill, Steven Robert Hayashi, Andrew William Miller
  • Publication number: 20180037433
    Abstract: Unwinding systems and methods are provided for unwinding a fiber from a bobbin. The unwinding system can include an axle defining a first axis extending an axial direction, a bobbin rotatably mounted around the axle, a pulley positioned to receive the fiber from the bobbin, wherein the pulley is rotatable around a second axis, and a sensor positioned between the bobbin and the pulley. The bobbin is moveable along the axial direction, and wherein the fiber extends tangentially from a surface of the bobbin.
    Type: Application
    Filed: August 3, 2016
    Publication date: February 8, 2018
    Inventors: Theodore Robert Grossman, Roger Antonio Aparicio, Martin Peter Gill, Steven Robert Hayashi, Andrew William Miller
  • Publication number: 20170173731
    Abstract: A method for shaping a ceramic matrix composite (CMC) sheet having a first surface and a second surface is presented. The method includes receiving an input signal representative of a predetermined shape and a type of the CMC sheet. Further, the method includes selecting a laser beam based on the received input signal. Also, the method includes projecting the selected laser beam on the CMC sheet to shape the CMC sheet into the predetermined shape.
    Type: Application
    Filed: December 18, 2015
    Publication date: June 22, 2017
    Inventors: Hongqiang Chen, Steven Robert Hayashi, Martin Kin-Fei Lee, Nitin Garg, Nolan Leander Cousineau, Derrick Wayne Knotts
  • Publication number: 20170144239
    Abstract: The polishing system includes a power supply. The polishing system also includes a container including an interior portion. The interior portion includes a conductive material thereon. The conductive material is electrically coupled to the power supply. The polishing system also includes an electrolytic solution disposed within the container. The electrolytic solution includes a plurality of abrasive particles. The polishing system further includes a flexible media disposed within the container. The container is configured to contain an object. The power supply configured to electrically couple to the object. Each of the electrolytic solution, the flexible media, and the abrasive particles is configured to partially polish the object substantially simultaneously.
    Type: Application
    Filed: November 25, 2015
    Publication date: May 25, 2017
    Inventors: Yuanfeng Luo, Steven Robert Hayashi, Adegboyega Masud Makinde, Andrew Lee Trimmer
  • Patent number: 9658385
    Abstract: Optically patterned waveguides and systems employing optically patterned waveguides are provided. The optically patterned waveguide is configured for use in a lighting system and arranged perpendicular to an overhead structure, such as a ceiling. The optically patterned waveguide includes major surfaces that are patterned with a plurality of elongated facets formed into the major surfaces and extending in a direction parallel to the length of the waveguide. The optically patterned waveguide provides illumination patterns having increased uniformity.
    Type: Grant
    Filed: May 29, 2015
    Date of Patent: May 23, 2017
    Assignee: General Electric Company
    Inventors: Mark Marshall Meyers, Steven Robert Hayashi
  • Publication number: 20170059676
    Abstract: A gradient coil comprises a curved conductor, which is tubular and has a general spiral shape. The curved conductor is formed by a process comprising depositing at least one non-conductive material layer by layer to form a substrate, and coating at least a portion of a surface of the substrate with a conductive material. The substrate has a shape matching with the general spiral shape of the curved conductor. Embodiments of the present disclosure further refer to a method for manufacturing the gradient coil.
    Type: Application
    Filed: August 26, 2016
    Publication date: March 2, 2017
    Inventors: Yanzhe Yang, Steven Robert Hayashi, Kevin Warner Flanagan, Prabhjot Singh, Jian Lin, Jean-Baptiste Mathieu, Kenneth Paul Zarnock, Thomas Kwok-Fah Foo
  • Publication number: 20170028492
    Abstract: An electrochemical machining system for machining a conductive work piece is provided. The system includes a drilling tool configured to remove material from the conductive work piece. The drilling tool is configured to advance within the conductive work piece along a tool path to form a bore hole having a variable geometry that extends through the conductive work piece when the material is removed therefrom. The system further includes an inspection device configured to determine a position of the drilling tool along the tool path, and a controller configured to communicate with the inspection device. The controller is further configured to compare the tool path to a nominal tool path, and determine a position error of said drilling tool, the position error defined by a difference between the tool path and the nominal tool path.
    Type: Application
    Filed: July 30, 2015
    Publication date: February 2, 2017
    Inventors: Andrew Lee Trimmer, Steven Robert Hayashi, Edward James Nieters, Jeremy Gordon McNamara
  • Publication number: 20160346856
    Abstract: An electroerosion machining system for trepanning and drilling operations is disclosed. The electroerosion machining system includes an electrode assembly configured to machine a desired configuration in a workpiece, a power supply configured to energize the electrode assembly and the workpiece to opposite electrical polarities, an electrolyte supply configured to pass an electrolyte between the electrode assembly and the workpiece, a working apparatus configured to move the electrode assembly relative to the workpiece, and a control system to control the power supply and the working apparatus. The electrode assembly further includes an electrode body in the form of a tube-shaped body, the tube-shaped body defining a hollow interior and one or more replaceable inserts affixed to the electrode body at a working end thereof positioned adjacent the workpiece, the one or more replaceable inserts constructed so as to be selectively attachable and detachable from the working end of the electrode body.
    Type: Application
    Filed: May 28, 2015
    Publication date: December 1, 2016
    Inventors: Yuanfeng Luo, Steven Robert Hayashi, Andrew Lee Trimmer, Dale Robert Lombardo, John Anthony Vogel