Patents by Inventor Vernon M. Benson
Vernon M. Benson 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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Publication number: 20190118496Abstract: Material preparation devices and related methods include a material or substrate assembly and an application assembly for applying a fiber material.Type: ApplicationFiled: December 14, 2018Publication date: April 25, 2019Inventors: Jason K. Slack, Christopher J. Madsen, Don C. Jones, Vernon M. Benson, Peter G. Turner, Ralph Douglas Cope, Kimberly Ann Ferrara, Anthony Dale Johnson, Michael James Case, Jesse Paul Brown, James Gargel, Steven Andrew Cope, Kyle Putnam Tarry
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Patent number: 10155348Abstract: A material preparation device is provided. The material preparation device includes a bias-ply assembly, a feedstock assembly and an application head. The bias-ply assembly is configured to pass a bias-ply backing material along a first path. The feedstock assembly is configured to pass a feedstock along a second path that crosses the first path at a select angle. The feedstock includes resin pre-impregnated fiber-reinforced material (pre-preg) having the fibers at a first orientation relative to an edge of the feedstock. The application head is configured to transfer the pre-preg from the feedstock to the bias-ply backing material at a location where the first path crosses the second path to form a bias-ply with the fibers of the pre-preg having a second, different orientation relative to an edge of the formed bias-ply.Type: GrantFiled: April 25, 2016Date of Patent: December 18, 2018Assignee: Northrop Grumman Innovation Systems, Inc.Inventors: Jason K. Slack, Christopher J. Madsen, Don C. Jones, Vernon M. Benson, Peter G. Turner, Ralph Douglas Cope, Kimberly Ann Ferrara, Anthony Dale Johnson, Michael James Case, Jesse Paul Brown, James Gargel, Steven Andrew Cope, Kyle Putnam Tarry
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Publication number: 20180154592Abstract: Apparatuses for forming a composite structure are configured to provide a tension at least partially along at least one ply of material as the at least one ply of material is supplied from a material feed assembly to a tool.Type: ApplicationFiled: February 1, 2018Publication date: June 7, 2018Inventors: Vernon M. Benson, Jason K. Slack, Todd A. Rosevear, James L. Harvey, Mark Roman, Timothy S. Olschewski
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Publication number: 20170080647Abstract: An induction heating compaction system is provided. The system includes an induction heating member and a compaction member. The induction heating member is configured to generate an electromagnetic field at a select frequency. The select frequency causes at least one of the fibers and matrix in pre-preg material to heat up. The compaction member has at least a portion that is made from a material that is transparent to the select frequency of the electromagnetic field generated by the induction heating member. The compaction member includes a cooling assembly that is configured and arranged to extract heat from the pre-preg material, while compacting the pre-preg material.Type: ApplicationFiled: November 3, 2016Publication date: March 23, 2017Inventors: Vernon M. Benson, David R. Machac, Bryan J. Loveless
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Patent number: 9527237Abstract: An induction heating compaction system is provided. The system includes an induction heating member and a compaction member. The induction heating member is configured to generate an electromagnetic field at a select frequency. The select frequency causes at least one of the fibers and matrix in pre-preg material to heat up. The compaction member has at least a portion that is made from a material that is transparent to the select frequency of the electromagnetic field generated by the induction heating member. The compaction member includes a cooling assembly that is configured and arranged to extract heat from the pre-preg material, while compacting the pre-preg material.Type: GrantFiled: January 4, 2013Date of Patent: December 27, 2016Assignee: ORBITAL ATK, INC.Inventors: Vernon M. Benson, David R. Machac, Brian J. Loveless
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Publication number: 20160236426Abstract: A material preparation device is provided. The material preparation device includes a bias-ply assembly, a feedstock assembly and an application head. The bias-ply assembly is configured to pass a bias-ply backing material along a first path. The feedstock assembly is configured to pass a feedstock along a second path that crosses the first path at a select angle. The feedstock includes resin pre-impregnated fiber-reinforced material (pre-preg) having the fibers at a first orientation relative to an edge of the feedstock. The application head is configured to transfer the pre-preg from the feedstock to the bias-ply backing material at a location where the first path crosses the second path to form a bias-ply with the fibers of the pre-preg having a second, different orientation relative to an edge of the formed bias-ply.Type: ApplicationFiled: April 25, 2016Publication date: August 18, 2016Inventors: Jason K. Slack, Christopher J. Madsen, Don C. Jones, Vernon M. Benson, Peter G. Turner, Ralph Douglas Cope, Kimberly Ann Ferrara, Anthony Dale Johnson, Michael James Case, Jesse Paul Brown, James Gargel, Steven Andrew Cope, Kyle Putnam Tarry
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Publication number: 20160167287Abstract: Apparatus and methods of stretch-forming pre-preg material are provided. In one example embodiment, a variable material stretch-forming apparatus comprises a stretch-forming assembly configured to stretch-form at least one section of a sheet of pre-preg material to a longer length than at least one other section of the sheet of pre-preg material before the sheet of pre-preg material is applied to a tool.Type: ApplicationFiled: February 22, 2016Publication date: June 16, 2016Inventors: Vernon M. Benson, Peter G. Turner
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Patent number: 9321220Abstract: A material preparation device is provided. The material preparation device includes a bias-ply assembly, a feedstock assembly and an application head. The bias-ply assembly is configured to pass a bias-ply backing material along a first path. The feedstock assembly is configured to pass a feedstock along a second path that crosses the first path at a select angle. The feedstock includes resin pre-impregnated fiber reinforced material (pre-preg) having the fibers at a first orientation relative to an edge of the feedstock. The application head is configured to transfer the pre-preg from the feedstock to the bias-ply backing material at a location where the first path crosses the second path to form a bias-ply with the fibers of the pre-preg having a second different orientation relative to an edge of the formed bias-ply.Type: GrantFiled: April 13, 2010Date of Patent: April 26, 2016Assignee: Orbital ATK, Inc.Inventors: Jason Slack, Christopher J. Madsen, Don C. Jones, Vernon M. Benson, Peter G. Turner, Ralph Douglas Cope, Kimberly Ann Ferrara, Anthony Dale Johnson, Michael James Case, Jesse Paul Brown, James Gargel, Steven Andrew Cope, Kyle Putnam Tarry
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Patent number: 9266279Abstract: Apparatus and methods of stretch-forming pre-preg material are provided. In one example embodiment, a variable material stretch-forming apparatus comprises a stretch-forming assembly configured to stretch-form at least one section of a sheet of pre-preg material to a longer length than at least one other section of the sheet of pre-preg material before the sheet of pre-preg material is applied to a tool.Type: GrantFiled: July 8, 2010Date of Patent: February 23, 2016Assignee: Orbital ATK, Inc.Inventors: Vernon M. Benson, Peter G. Turner
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Patent number: 8366981Abstract: A composite structure is provided. The structure includes at least one ply of preimpregnated material formed into a curved elongated member of continuous fibers onto a mandrel. The fibers have a select orientation. The curved elongated member has a length and a cross-sectional geometry that varies along the length.Type: GrantFiled: September 15, 2010Date of Patent: February 5, 2013Assignee: Alliant Techsystems Inc.Inventors: Vernon M. Benson, Jason K. Slack, Todd A. Rosevear, James L. Harvey, Mark Roman, Timothy Olschewski
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Publication number: 20130004730Abstract: A composite structure is provided. The structure includes at least one ply of preimpregnated material formed into a curved elongated member of continuous fibers onto a mandrel. The fibers have a select orientation. The curved elongated member has a length and a cross-sectional geometry that varies along the length.Type: ApplicationFiled: September 14, 2012Publication date: January 3, 2013Inventors: Vernon M. Benson, Jason Slack, Todd A. Rosevear, James L. Harvey, Mark Roman, Timothy Olschewski
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Patent number: 8226787Abstract: Apparatuses, systems and methods for forming elongated composite structural members are provided. One disclosed method includes providing a substantially elongated mandrel having an exterior surface exhibiting a desired geometry. A plurality of plies of fiber material preimpregnated with a thermosetting resin are laid up and pressed onto the mandrel, Pressing the plies of material may include passing one or more rollers over the mandrel and over the plurality of plies along a length of the mandrel. The roller or rollers may be at least partially complementary in shape with the mandrel while maintaining the plies of material in a substantially uncured state during the pressing. The method may include sequentially passing a plurality of rollers over the mandrel and the plies of material. The method may also include configuring a first roller to partially complementarily engage the mandrel and configuring another roller to substantially fully complementarily engage the mandrel.Type: GrantFiled: July 31, 2007Date of Patent: July 24, 2012Assignee: Alliant Techsystems Inc.Inventors: Vernon M. Benson, Jason Slack, Todd A. Rosevear
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Publication number: 20120007278Abstract: Apparatus's and methods of stretch-forming pre-preg material are provided. In one example embodiment a variable material stretch forming apparatus comprises a stretch-forming assembly configured to stretch-form at least one section along a width of a sheet of pre-preg material to a longer length than at least one other section along the width of the sheet of pre-preg material before the sheet of pre-preg material is applied to a tool.Type: ApplicationFiled: July 8, 2010Publication date: January 12, 2012Inventors: Vernon M. Benson, Peter G. Turner
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Patent number: 8052823Abstract: Stiffener tool positioning apparatus and methods are provided. In one embodiment, the apparatus includes a base, a first flipper member and second flipper member. The first flipper member is slide-ably attached to the base. The first flipper member is also configured to selectively attach a first mandrel thereon and to rotate the first mandrel. The second flipper member is also slide-ably attached to the base. The first and second flipper members are slide-ably positioned select distances from each other on the base in embodiments. The second mandrel is further configured to attach a second mandrel thereon and to rotate the second mandrel.Type: GrantFiled: January 30, 2009Date of Patent: November 8, 2011Assignee: Alliant Techsystems Inc.Inventors: Vernon M. Benson, Douglas G. Harris, Jason K. Slack, Michael D. Cimbalista, Jr., Nicklaus C. Kimball, Timothy S. Olschewski, Jeremy D. Palmer
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Patent number: 8042594Abstract: A method and system for a fiber compaction device with interdependent segment travel is described. A compaction device structure supports a series of individual interdependent segments including a compaction surface. Each segment also includes an opening in which a presser member can be located. The presser members consist of either an elastomeric bladder filled with an incompressible fluid or individual pistons that are manifolded together with a fixed volume of incompressible fluid. The presser members create an interdependence in segment positions such that if one or more segments are displaced the others move to balance the segment positions. Having a fixed volume of incompressible fluid allows the segments to work interdependently, thus guaranteeing that the average section position will be the nominal position and eliminating the need for a fixed center section.Type: GrantFiled: June 28, 2006Date of Patent: October 25, 2011Assignee: Alliant Techsystems Inc.Inventors: Lloyd G. Miller, Douglas G. Harris, Vernon M. Benson, Keith G. Shupe, Kevin L. Wade
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Publication number: 20110247743Abstract: A material preparation device is provided. The material preparation device includes a bias-ply assembly, a feedstock assembly and an application head. The bias-ply assembly is configured to pass a bias-ply backing material along a first path. The feedstock assembly is configured to pass a feedstock along a second path that crosses the first path at a select angle. The feedstock includes resin pre-impregnated fiber reinforced material (pre-preg) having the fibers at a first orientation relative to an edge of the feedstock. The application head is configured to transfer the pre-preg from the feedstock to the bias-ply backing material at a location where the first path crosses the second path to form a bias-ply with the fibers of the pre-preg having a second different orientation relative to an edge of the formed bias-ply.Type: ApplicationFiled: April 13, 2010Publication date: October 13, 2011Inventors: Jason K. Slack, Christopher J. Madsen, Don C. Jones, Vernon M. Benson, Peter G. Turner, Ralph Douglas Cope, Kimberly Ann Ferrara, Anthony Dale Johnson, Michael James Case, Jesse Paul Brown, James Gargel, Steven Andrew Cope, Kyle Putnam Tarry
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Publication number: 20110003111Abstract: A composite structure is provided. The structure includes at least one ply of preimpregnated material formed into a curved elongated member of continuous fibers onto a mandrel. The fibers have a select orientation. The curved elongated member has a length and a cross-sectional geometry that varies along the length.Type: ApplicationFiled: September 15, 2010Publication date: January 6, 2011Inventors: Vernon M. Benson, Jason Slack, Todd A. Rosevear, James L. Harvey, Mark Roman, Timothy Olschewski
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Patent number: 7819651Abstract: A composite structure is provided. In one embodiment, the structure includes at least one ply of preimpregnated material formed into a curved elongated member of continuous fibers onto a mandrel. The fibers have a select orientation and the curved elongated member has a defined length. The curved elongated member further has a cross-sectional geometry that varies along the length.Type: GrantFiled: November 25, 2008Date of Patent: October 26, 2010Assignee: Alliant Techsystems Inc.Inventors: Vernon M. Benson, Jason K. Slack, Todd A. Rosevear, James L. Harvey, Mark Roman, Timothy Olschewski
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Patent number: 7820092Abstract: Methods of forming an elongated composite structural member are provided. One method includes, providing a substantially elongated mandrel having an exterior surface exhibiting a desired geometry. Laying up a first ply of preimpregnated fiber reinforced material over the mandrel. Applying a force to the first ply to establish a desired amount of tension within the first ply and then pressing the first ply onto the mandrel in a conformal manner. This includes passing at least one roller over the mandrel and the first ply while maintaining the desired amount of tension within the first ply. The at least one roller is at least partially complementary in shape with the mandrel.Type: GrantFiled: November 25, 2008Date of Patent: October 26, 2010Assignee: Alliant Techsystems Inc.Inventors: Vernon M. Benson, Jason K. Slack, Todd A. Rosevear, James L. Harvey, Mark Roman, Timothy Olschewski
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Patent number: 7767128Abstract: Method of forming a curved composite structure are provided. In one embodiment, the method includes contacting at least one ply of preimpregnated material on a first surface of a curved mandrel. The first surface of the mandrel has a first radius of curvature. The mandrel further has at least one second surface that has a second radius of curvature. A tension gradient is introduced on the ply adjacent to the first radius of curvature and the ply is then pressed over the curved mandrel to form the curved composite structure.Type: GrantFiled: November 25, 2008Date of Patent: August 3, 2010Assignee: Alliant Techsystems Inc.Inventors: Vernon M. Benson, Jason K. Slack, Todd A. Rosevear, James L. Harvey, Mark Roman, Timothy Olschewski