Patents by Inventor Thomas K Tsotsis
Thomas K Tsotsis 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: 11919035Abstract: Methods, apparatus, systems and articles of manufacture are disclosed to prepare an aircraft surface, including depositing a first solution on a substrate on the aircraft surface, the substrate having a first charge, the first solution having a second charge opposite the first charge, the first solution including a carrier fluid, removing a first amount of the first solution deposited on the substrate to form a first layer on the substrate, depositing a second solution on the first layer, the second solution having the first charge, the second solution including the carrier fluid, and removing a second amount of the second solution deposited on the first layer to form a second layer on the first layer to prepare the aircraft surface.Type: GrantFiled: June 29, 2021Date of Patent: March 5, 2024Assignee: The Boeing CompanyInventor: Thomas K. Tsotsis
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Patent number: 11407199Abstract: Disclosed herein are laminates that include a layer containing a metal-coated fabric. The laminate may also include a layer or layers of an organic polymeric matrix composite. In accordance with certain embodiments, the matrix composite includes a thermosetting or thermoplastic resin matrix with parallel-oriented reinforcing fibers embedded therein, interposed between the metal-coated fabric layers.Type: GrantFiled: April 15, 2009Date of Patent: August 9, 2022Assignee: THE BOEING COMPANYInventor: Thomas K. Tsotsis
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Publication number: 20220048065Abstract: Methods, apparatus, systems and articles of manufacture are disclosed to prepare an aircraft surface, including depositing a first solution on a substrate on the aircraft surface, the substrate having a first charge, the first solution having a second charge opposite the first charge, the first solution including a carrier fluid, removing a first amount of the first solution deposited on the substrate to form a first layer on the substrate, depositing a second solution on the first layer, the second solution having the first charge, the second solution including the carrier fluid, and removing a second amount of the second solution deposited on the first layer to form a second layer on the first layer to prepare the aircraft surface.Type: ApplicationFiled: June 29, 2021Publication date: February 17, 2022Inventor: Thomas K. Tsotsis
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Patent number: 11186045Abstract: A system for manufacturing a rotor blade comprises a first tooling, positioned at a factory location and configured to assemble a first blade module, comprising a first-module skin and a first-module spar, each comprising a first thermoplastic polymer and a first reinforcement material. The system also comprises a second tooling, configured to assemble a second blade module, comprising a second-module skin and a second-module spar, each comprising a second thermoplastic polymer and a second reinforcement material. The system further comprises a first support, positioned at a field location and configured to receive the first blade module, and a second support, positioned at the field location and configured to receive the second blade module. The system also comprises a spar welding assembly, positioned at the field location and configured to join the first-module spar with the second-module spar.Type: GrantFiled: September 11, 2020Date of Patent: November 30, 2021Assignee: The Boeing CompanyInventors: Marc R. Matsen, Thomas K. Tsotsis
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Patent number: 11097495Abstract: A method for manufacturing a composite structure. The method includes depositing a plurality of thermoplastic particles onto at least one of a surface of a filler member and a surface of a structural member. The method further includes assembling the filler member with the structural member such that the plurality of thermoplastic particles are disposed proximate an interface between the filler member and the structural member.Type: GrantFiled: October 23, 2019Date of Patent: August 24, 2021Assignee: The Boeing CompanyInventor: Thomas K. Tsotsis
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Patent number: 11066561Abstract: The present disclosure provides a barrier-coating structure that includes a polymer-matrix composite having a first surface and a second surface. The barrier-coating structure includes a flexible layer having a first surface and a second surface and a sol-gel layer having a first surface and a second surface. The first surface of the flexible layer contacts the second surface of the flexible layer. The barrier-coating structure includes a barrier layer having a first surface and a second surface. The sol-gel and/or the barrier layer may comprise one or more reactive substituents. The first surface of the barrier layer may be a laser-ablated surface.Type: GrantFiled: April 4, 2019Date of Patent: July 20, 2021Assignee: THE BOEING COMPANYInventor: Thomas K. Tsotsis
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Publication number: 20210122124Abstract: A method for manufacturing a composite structure. The method includes depositing a plurality of thermoplastic particles onto at least one of a surface of a filler member and a surface of a structural member. The method further includes assembling the filler member with the structural member such that the plurality of thermoplastic particles are disposed proximate an interface between the filler member and the structural member.Type: ApplicationFiled: October 23, 2019Publication date: April 29, 2021Applicant: The Boeing CompanyInventor: Thomas K. Tsotsis
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Publication number: 20210023813Abstract: A composite manufacturing method includes the step of drawing a nonwoven fabric formed of continuous fibers through a slurry of discontinuous fibers suspended in a dispersive liquid to yield a fiber-modified interlayer comprising a network of said discontinuous fibers attached to said nonwoven fabric.Type: ApplicationFiled: October 2, 2020Publication date: January 28, 2021Applicant: The Boeing CompanyInventors: Thomas K. Tsotsis, Joseph E. Sprengard
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Publication number: 20200406560Abstract: A system for manufacturing a rotor blade comprises a first tooling, positioned at a factory location and configured to assemble a first blade module, comprising a first-module skin and a first-module spar, each comprising a first thermoplastic polymer and a first reinforcement material. The system also comprises a second tooling, configured to assemble a second blade module, comprising a second-module skin and a second-module spar, each comprising a second thermoplastic polymer and a second reinforcement material. The system further comprises a first support, positioned at a field location and configured to receive the first blade module, and a second support, positioned at the field location and configured to receive the second blade module. The system also comprises a spar welding assembly, positioned at the field location and configured to join the first-module spar with the second-module spar.Type: ApplicationFiled: September 11, 2020Publication date: December 31, 2020Applicant: The Boeing CompanyInventors: Marc R. Matsen, Thomas K. Tsotsis
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Patent number: 10814559Abstract: A method of manufacturing a rotor blade includes (1) assembling a first blade module that defines a first-module span axis and includes a first-module skin and a first- module spar, and each of the first-module skin and the first-module spar includes a first thermoplastic polymer and reinforcement material; (2) assembling a second blade module that defines a second-module span axis and includes a second-module skin and a second- module spar, and each of the second-module skin and the second-module spar includes a second thermoplastic polymer and reinforcement material; (3) transporting the first blade module and the second blade module to a field location; (4) aligning, at the field location, the first-module span axis with the second-module span axis to define an aligned pair of modules; and (5) heating a portion of the aligned pair of modules to form a weld joint between the first-module spar and the second-module spar.Type: GrantFiled: December 20, 2018Date of Patent: October 27, 2020Assignee: The Boeing CompanyInventors: Marc R. Matsen, Thomas K. Tsotsis
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Patent number: 10787591Abstract: Composites comprising at least one silicon-oxy-carbide (SOC) layer deposited onto a polymeric matrix substrate to enhance their thermo-oxidative stability are provided. The SOC layer is formed onto the polymeric matrix substrate by atmospheric plasma deposition to produce an thermo-oxidative barrier coating or an adhesion-promoting layer to enable the deposition of a variety of known (or future developed) metallic and/or ceramic materials as oxygen and/or thermal barriers.Type: GrantFiled: March 15, 2013Date of Patent: September 29, 2020Assignee: THE BOEING COMPANYInventors: Thomas K. Tsotsis, Marvi A. Matos, Alpana Ranade, Laura M. Murphy
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Publication number: 20200198252Abstract: A system (100), for manufacturing a rotor blade (112), comprises a first tooling (170), positioned at a factory location (114) and configured to assemble a first blade module (116), comprising a first-module skin (118) and a first-module spar (120), each comprising a first thermoplastic polymer (122) and a first reinforcement material (124). The system (100) comprises a second tooling (172), configured to assemble a second blade module (126), comprising a second-module skin (128) and a second-module spar (130), each comprising a second thermoplastic polymer (132) and a second reinforcement material (134). The system (100) comprises a first support (160), positioned at a field location (140) and configured to receive the first blade module (116), and a second support (162), positioned at the field location (140) and configured to receive the second blade module (126).Type: ApplicationFiled: December 20, 2018Publication date: June 25, 2020Applicant: The Boeing CompanyInventors: Marc R. Matsen, Thomas K. Tsotsis
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Publication number: 20190376199Abstract: Systems and methods are provided for rapidly producing complex aircraft assembly tools using a meltable substrate and electrodeposition. One embodiment is a method that includes forming a meltable substrate into a model that corresponds with a shape of the aircraft assembly tool, wherein the meltable substrate is integrated with an electrically conductive material. The method also includes electrodepositing metal onto the outer surface of the model to form a metal frame having the shape of the aircraft assembly tool, the metal frame having at least one hole. The method further includes melting the model to remove the meltable substrate and the electrically conductive material from the metal frame via the hole to form a hollow metal tool having the shape of the aircraft assembly tool.Type: ApplicationFiled: June 11, 2018Publication date: December 12, 2019Inventor: Thomas K. Tsotsis
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Patent number: 10442116Abstract: A tool including a tool body, the tool body including a substrate having a tool-side surface, an intermediate layer positioned over the tool-side surface, and an outer layer positioned over the intermediate layer, the outer layer including a metallic material.Type: GrantFiled: July 28, 2017Date of Patent: October 15, 2019Assignee: The Boeing CompanyInventor: Thomas K. Tsotsis
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Publication number: 20190233661Abstract: The present disclosure provides a barrier-coating structure that includes a polymer-matrix composite having a first surface and a second surface. The barrier-coating structure includes a flexible layer having a first surface and a second surface and a sol-gel layer having a first surface and a second surface. The first surface of the flexible layer contacts the second surface of the flexible layer. The barrier-coating structure includes a barrier layer having a first surface and a second surface. The sol-gel and/or the barrier layer may comprise one or more reactive substituents. The first surface of the barrier layer may be a laser-ablated surface.Type: ApplicationFiled: April 4, 2019Publication date: August 1, 2019Inventor: Thomas K. Tsotsis
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Patent number: 10301750Abstract: The present invention relates to a continuous, multicellular, hollow carbon fiber wherein the fiber structure includes a substantially hollow fiber and multiple internal walls defining multiple integral internal hollow fibers such that the fiber structure comprises a honeycomb-like cross section.Type: GrantFiled: November 20, 2012Date of Patent: May 28, 2019Assignee: The Boeing CompanyInventors: Thomas K. Tsotsis, Jeff Haggard
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Patent number: 10253192Abstract: The present disclosure provides a barrier-coating structure that includes a polymer-matrix composite having a first surface and a second surface. The barrier-coating structure includes a flexible layer having a first surface and a second surface and a sol-gel layer having a first surface and a second surface. The first surface of the flexible layer contacts the second surface of the flexible layer. The barrier-coating structure includes a barrier layer having a first surface and a second surface. The sol-gel and/or the barrier layer may comprise one or more reactive substituents. The first surface of the barrier layer may be a laser-ablated surface.Type: GrantFiled: August 29, 2016Date of Patent: April 9, 2019Assignee: THE BOEING COMPANYInventor: Thomas K. Tsotsis
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Patent number: 10232571Abstract: A system and method for forming an item from a material, which may include elongated fibers and/or stretched broken fibers. The material is placed on a first clamping portion, which is placed on a fixture. A second clamping portion is placed against the material and the first clamping portion and secured together, forming a clamping assembly. The clamping assembly is removed from the fixture and placed on a first die portion, having a first profile. A second die portion is also provided, having a second profile. In forming the item, at least one of the first die portion and the second die portion are moved toward each other such that a second surface of the first die portion and a first surface of the second die portion contact and form the material into the item generally replicating the first profile and the second profile.Type: GrantFiled: September 22, 2015Date of Patent: March 19, 2019Assignee: the boeing companyInventors: Mike P. Matlack, Stephen J. Morgan, Thomas K. Tsotsis, James R. Fox, Randall D. Wilkerson
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Patent number: 10226905Abstract: A system and method for forming an item from a material, which may include elongated fibers and/or stretched broken fibers. The material is placed on a first clamping portion, which is placed on a fixture. A second clamping portion is placed against the material and the first clamping portion and secured together, forming a clamping assembly. The clamping assembly is removed from the fixture and placed on a first die portion, having a first profile. A second die portion is also provided, having a second profile. In forming the item, at least one of the first die portion and the second die portion are moved toward each other such that a second surface of the first die portion and a first surface of the second die portion contact and form the material into the item generally replicating the first profile and the second profile.Type: GrantFiled: September 22, 2015Date of Patent: March 12, 2019Assignee: the boeing companyInventors: Mike P. Matlack, Stephen J. Morgan, Thomas K. Tsotsis, James R. Fox, Randall D. Wilkerson
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Publication number: 20190039264Abstract: A method for manufacturing a preform includes heating one or more layers of fibrous material containing a plurality of discontinuous structural fibers and a predetermined percentage of thermoplastic material to a first temperature above a softening temperature of the thermoplastic material, forming the one or more layers of fibrous material containing the thermoplastic material into a predetermined shape including at least one raised or depressed region, and cooling the one or more layers of fibrous material having the predetermined shape to a second temperature below the softening temperature to harden the thermoplastic material. The predetermined shape of the one or more layers of fibrous material is retained by the hardened thermoplastic material, and the cooled one or more layers of fibrous material containing the thermoplastic material are permeable.Type: ApplicationFiled: August 3, 2017Publication date: February 7, 2019Applicant: The Boeing CompanyInventor: Thomas K. Tsotsis