Patents by Inventor Vlastimil Kunc
Vlastimil Kunc 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: 20240066793Abstract: A method of manufacturing an article is provided. The method includes feeding a polymeric material into an extruder including a nozzle, and feeding a continuous fiber into the extruder, the continuous fiber and the polymeric material together forming a molding compound. A three-dimensional preform is formed by discharging the molding compound from the nozzle onto a deposition surface. A mold charge is formed by positioning the three-dimensional preform within a mold that includes a top mold component and a bottom mold component. The mold charge is compression molded within the mold to form a finished article.Type: ApplicationFiled: August 23, 2023Publication date: February 29, 2024Inventors: Vipin Kumar, Ahmed A. Hassen, Vlastimil Kunc, Cole Nielsen, David Nuttall
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Patent number: 11873382Abstract: The current embodiments include all-polymeric protective material for mitigating lightning strike damage. The protective material includes a hybrid matrix comprising PANI and MXene dispersed within a thermosetting epoxy resin. This hybrid matrix can be painted, printed, or applied as a conductive polymeric layer to a FRCP structure, for example an aircraft fuselage, wing, empennage, control surface (aileron, flap, slats, rudder, elevator) or a wind turbine blade. The protective material not only withstands lightning strikes, but also functions as shielding against electromagnetic interference and is corrosion-resistant and lightweight.Type: GrantFiled: March 30, 2022Date of Patent: January 16, 2024Assignee: UT-BATTELLE, LLCInventors: Vipin Kumar, Ahmed A. Hassen, Christopher J. Hershey, Seokpum Kim, Vlastimil Kunc, John M. Lindahl
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Publication number: 20230339186Abstract: Slicer system for generating molecular dynamic graded lattice structures that can be used as infill for additively manufactured articles. Molecular dynamically generated lattice infill is based on force balancing a node distribution instead of a circle packing. Field data can be utilized to adjust the spacing of the node distribution according to a force balance equilibrium model that accounts for the field expected to be experienced by the article being additively manufactured. The resultant non-uniform honeycomb structures from force-balancing robustly and efficiently address the connection issues with traditional non-uniform lattice structures.Type: ApplicationFiled: June 30, 2023Publication date: October 26, 2023Inventors: Seokpum Kim, Ahmed Arabi Hassen, Lonnie J. Love, Vlastimil Kunc
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Patent number: 11794415Abstract: A simulation-assisted additive manufacturing system and method for generating an anisotropic compensation to account for non-uniform deformation due to additive manufacturing and service loading. The predicted deformation may not be fully defined. The present disclosure provides a system and method for estimating the missing deformation data through regression analysis. The present disclosure also provides an integrated framework where the various simulated-assisted design modules are configured for two-way communication and sharing access to changes to the model.Type: GrantFiled: September 15, 2021Date of Patent: October 24, 2023Assignee: UT-Battelle, LLCInventors: Seokpum Kim, Ahmed A. Hassen, John M. Lindahl, Lonnie J. Love, Vlastimil Kunc, Thomas Feldhausen
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Patent number: 11738515Abstract: Systems and methods for generating molecular dynamic graded lattice structures that can be used as infill for additively manufactured articles. Molecular dynamically generated lattice infill is based on force balancing a node distribution instead of a circle packing. Field data can be utilized to adjust the spacing of the node distribution according to a force balance equilibrium model that accounts for the field expected to be experienced by the article being additively manufactured. The resultant non-uniform honeycomb structures from force-balancing robustly and efficiently address the connection issues with traditional non-uniform lattice structures.Type: GrantFiled: December 8, 2021Date of Patent: August 29, 2023Assignee: UT-Battelle, LLCInventors: Seokpum Kim, Ahmed Arabi Hassen, Lonnie J. Love, Vlastimil Kunc
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Patent number: 11623395Abstract: An apparatus and device for creating a vertical strengthening feature within a 3D printed article of manufacture for improving mechanical performance in the Z-direction. Fill material is deposited in voids vertically crossing multiple layers during the build of 3D printing. The device includes a penetrating extension that fits within the void to create a vertical strengthening feature via heat and/or extruded fill material. The size and/or movement of the heated extension can impact the void side walls to reflow the build material and blend the layers together within the void side walls.Type: GrantFiled: October 25, 2021Date of Patent: April 11, 2023Assignee: UT-BATTELLE, LLCInventors: Vlastimil Kunc, Seokpum Kim, John M. Lindahl, Jordan A. Failla, Chad E. Duty
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Patent number: 11602898Abstract: Systems and methods for generating graded lattice structures that can be used as infill for additively manufactured articles. Tailored sectioning and field-based smoothing are modified polygon, e.g., circle, packing algorithms that adjust the size of the circles based on physical field data to adapt the infill generation process to a field expected to be experienced by the article. Molecular dynamically generated lattice infill is based on force balancing a node distribution instead of a circle packing. Field data can be utilized to adjust the spacing of the node distribution according to a force balance equilibrium model that accounts for the field expected to be experienced by the article being additively manufactured. The resultant non-uniform honeycomb structures from tailored sectioning, field-based smoothing, and force-balancing robustly and efficiently address the connection issues with traditional non-uniform lattice structures.Type: GrantFiled: May 28, 2021Date of Patent: March 14, 2023Assignee: UT-Battelle, LLCInventors: Seokpum Kim, John C. Bowers, Kenneth Stephenson, Vlastimil Kunc, Ahmed Arabi Hassen, Lonnie J. Love, Gregory D. Dreifus
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Patent number: 11518073Abstract: An improved method for obtaining high fiber volume fraction, long fiber injection molded articles is provided. According to one embodiment, the method includes forming an injection molding feedstock by cutting pre-impregnated fiber-reinforced tape into platelets. The platelets can be coated with a thin layer of polymer to allow sliding of the platelets with respect to each other at the early stages of plastication, rather than forcing relative motion of fibers with respect to each other. The method can further include the dispersion of material only in the final stages of the injection molding screw to promote gentle motion of the feedstock at the earlier stages of the plastication process. The method allows improvement of mechanical properties of articles manufactured with equipment and techniques that are prevalent in high volume automotive and consumer industries.Type: GrantFiled: November 20, 2020Date of Patent: December 6, 2022Assignee: UT-BATTELLE, LLCInventors: Vlastimil Kunc, Ahmed A. Hassen, John M. Lindahl, Seokpum Kim
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Publication number: 20220315774Abstract: A polymeric adhesive film including a conductive filler of polyaniline (PANI) and MXene is provided. The adhesive film can be painted, printed, or applied to different substrate structures, including aircraft and wind turbine blades. The adhesive film has potential as a fatigue sensor, a strain sensor, a gas sensor, a humidity sensor, and a temperature sensor, by non-limiting example. In one embodiment, a force sensing material includes a conductive filler of PANI and MXene within an organic or polymer matrix. The force sensing material is used to measure local mechanical strain by detecting the change in electrical conductivity induced by the mechanical strain. The force sensing material can also be used in other applications where local strain changes, including the detection of local humidity and local temperature.Type: ApplicationFiled: March 30, 2022Publication date: October 6, 2022Inventors: Vipin Kumar, Justin C. Condon, Ahmed A. Hassen, Christopher J. Hershey, Seokpum Kim, Vlastimil Kunc, John M. Lindahl
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Publication number: 20220315733Abstract: The current embodiments include all-polymeric protective material for mitigating lightning strike damage. The protective material includes a hybrid matrix comprising PANI and MXene dispersed within a thermosetting epoxy resin. This hybrid matrix can be painted, printed, or applied as a conductive polymeric layer to a FRCP structure, for example an aircraft fuselage, wing, empennage, control surface (aileron, flap, slats, rudder, elevator) or a wind turbine blade. The protective material not only withstands lightning strikes, but also functions as shielding against electromagnetic interference and is corrosion-resistant and lightweight.Type: ApplicationFiled: March 30, 2022Publication date: October 6, 2022Inventors: Vipin Kumar, Ahmed A. Hassen, Christopher J. Hershey, Seokpum Kim, Vlastimil Kunc, John M. Lindahl
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Publication number: 20220157499Abstract: A method for producing a bonded magnet, comprising: (i) low-shear compounding of a thermoplastic polymer and magnetic particles to form an initial homogeneous mixture thereof; (ii) feeding the initial homogeneous mixture into a plasticator comprising a low-shear single screw rotating unidirectionally toward a die orifice and housed within a heated barrel to result in heating of the initial homogeneous mixture until the thermoplastic polymer melts and forms a further homogeneous mixture, wherein said further homogeneous mixture is transported within threads of the single screw towards the die orifice and exits the die orifice as a solid pellet; (iii) conveying the solid pellet into a mold and compression molding the pellet in the mold, to form the bonded magnet, wherein the bonded magnet possesses a magnetic particle loading of at least 80 vol % and exhibits one or more magnetic properties varying by less than 5% throughout the bonded magnet.Type: ApplicationFiled: November 18, 2021Publication date: May 19, 2022Inventors: Uday Kumar Vaidya, Mariappan Parans Paranthaman, Vlastimil Kunc, Ahmed A. Hassen
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Publication number: 20220143918Abstract: Systems and methods for generating molecular dynamic graded lattice structures that can be used as infill for additively manufactured articles. Molecular dynamically generated lattice infill is based on force balancing a node distribution instead of a circle packing. Field data can be utilized to adjust the spacing of the node distribution according to a force balance equilibrium model that accounts for the field expected to be experienced by the article being additively manufactured. The resultant non-uniform honeycomb structures from force-balancing robustly and efficiently address the connection issues with traditional non-uniform lattice structures.Type: ApplicationFiled: December 8, 2021Publication date: May 12, 2022Inventors: Seokpum Kim, Ahmed Arabi Hassen, Lonnie J. Love, Vlastimil Kunc
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Patent number: 11325281Abstract: A method for rapid manufacturing of three dimensional discontinuous fiber preforms is provided. The method includes the deposition of a polymeric material containing fibers on a surface to form a tailored charge for compression molding. The reinforced polymeric material may be a thermoplastic or a reactive polymer with viscosity low enough to allow flow through an orifice during deposition, yet high enough zero shear viscosity to retain the approximate shape of the deposited charge. The material can be deposited in a predetermined pattern to induce the desired mechanical properties through alignment of the fibers. This deposition can be performed in a single layer or in multiple layers. The alignment is achieved passively by shear alignment of the fibers or actively through fiber orientation control or mixing. The fibers can be of the desired material, length, and morphology, including short and long filaments.Type: GrantFiled: July 23, 2019Date of Patent: May 10, 2022Assignee: UT-BATTELLE, LLCInventors: Vlastimil Kunc, Craig A. Blue, Ahmed A. Hassen, John M. Lindahl, Lonnie J. Love, Brian K. Post
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Publication number: 20220088881Abstract: A simulation-assisted additive manufacturing system and method for generating an anisotropic compensation to account for non-uniform deformation due to additive manufacturing and service loading. The predicted deformation may not be fully defined. The present disclosure provides a system and method for estimating the missing deformation data through regression analysis. The present disclosure also provides an integrated framework where the various simulated-assisted design modules are configured for two-way communication and sharing access to changes to the model.Type: ApplicationFiled: September 15, 2021Publication date: March 24, 2022Inventors: Seokpum Kim, Ahmed A. Hassen, John M. Lindahl, Lonnie J. Love, Vlastimil Kunc, Thomas Feldhausen
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Patent number: 11267201Abstract: An assembly for additive manufacturing includes a build housing including a base, a print head, and a print head support connected to the base for supporting the print head above the base. A driver system is provided for moving the print head and the base relative to one another. A build platform comprising a build support and at least one platen. The build support can be detachably engageable to the housing. The platens can be detachably engageable to the build support. The build support can include registration structure for registering the position of the build support relative to the build housing. A method of additive manufacturing is also disclosed.Type: GrantFiled: March 12, 2020Date of Patent: March 8, 2022Assignee: UT-BATTELLE, LLCInventors: Vlastimil Kunc, Ahmed A. Hassen, Brian K. Post, David W. Nuttall, John M. Lindahl, Lonnie J. Love, Tim Deluca, Mike Walch, Benjamin J. Hedger
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Publication number: 20220042494Abstract: A method of manufacturing a wind turbine blade with integrated lightning strike protection is provided. The method includes forming a plurality of fiber reinforced plies having carbonized textile-grade PAN fibers. The fiber reinforced plies are then stacked on a surface of a mold, wetted with a resin, and cured to form at least part of a wind turbine blade. Because the textile-grade PAN fibers are electrically conductive, the resultant structure provides both electrical conductivity and structural integrity. Laboratory testing of carbon fiber structures against simulated lightning strikes demonstrated high resilience due to their high electrical conductivity both in-plane and in through-thickness directions, with no significant damages, e.g., fiber breakage, resin evaporation, or delamination. High-temperature epoxy helped to improve the performance of the CFRP against the lightning strikes.Type: ApplicationFiled: August 10, 2021Publication date: February 10, 2022Inventors: Vipin Kumar, Vlastimil Kunc, Merlin Theodore
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Publication number: 20220040920Abstract: An apparatus and device for creating a vertical strengthening feature within a 3D printed article of manufacture for improving mechanical performance in the Z-direction. Fill material is deposited in voids vertically crossing multiple layers during the build of 3D printing. The device includes a penetrating extension that fits within the void to create a vertical strengthening feature via heat and/or extruded fill material. The size and/or movement of the heated extension can impact the void side walls to reflow the build material and blend the layers together within the void side walls.Type: ApplicationFiled: October 25, 2021Publication date: February 10, 2022Applicant: UT-BATTELLE, LLCInventors: Vlastimil Kunc, Seokpum KIM, John M. LINDAHL, Jordan A. Failla, Chad E. Duty
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Patent number: 11199517Abstract: A structural health monitoring method is provided that utilizes self-sensing printed polymer structures. The method is based on resistivity properties of conductive materials, which can be integrated to a 3D printed polymer structure during additive manufacturing. An article to be monitored has at least one 3D printed polymer structure including a circuit comprising at least one conductive pathway extending through a non-conductive material. The resistance across the circuit is measured during or after loading of the article to determine a resistance value. The measured resistance value is compared to a known resistance value, and based on the comparison, a defect can be detected in the 3D printed polymer structure. Structural health monitoring systems and articles with integrated structural health monitoring are also provided.Type: GrantFiled: August 13, 2019Date of Patent: December 14, 2021Assignee: UT-Battelle, LLCInventors: Vlastimil Kunc, Ahmed A. Hassen, Pooran C. Joshi, Seokpum Kim, John M. Lindahl, Chad E. Duty, Jordan A. Failla, Tyler C. H. Smith
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Publication number: 20210370606Abstract: Systems and methods for generating graded lattice structures that can be used as infill for additively manufactured articles. Tailored sectioning and field-based smoothing are modified polygon, e.g., circle, packing algorithms that adjust the size of the circles based on physical field data to adapt the infill generation process to a field expected to be experienced by the article. Molecular dynamically generated lattice infill is based on force balancing a node distribution instead of a circle packing. Field data can be utilized to adjust the spacing of the node distribution according to a force balance equilibrium model that accounts for the field expected to be experienced by the article being additively manufactured. The resultant non-uniform honeycomb structures from tailored sectioning, field-based smoothing, and force-balancing robustly and efficiently address the connection issues with traditional non-uniform lattice structures.Type: ApplicationFiled: May 28, 2021Publication date: December 2, 2021Inventors: Seokpum Kim, John C. Bowers, Kenneth Stephenson, Vlastimil Kunc, Ahmed Arabi Hassen, Lonnie J. Love, Gregory D. Dreifus
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Patent number: 11111359Abstract: A method of forming a low-density three-dimensional article is provided. The method includes printing a low-density composition on a substrate to form at least one layer comprising the low-density composition. The low-density composition includes a (P) polymer component and (M) a microsphere component in a ratio by volume (P):(M). The method also includes selectively controlling a density of the low-density composition during printing to give the at least one layer on the substrate. Selectively controlling the density of the low-density composition includes varying the ratio (P):(M) during printing. The method further includes repeating the printing and selectively controlling the density of the low-density composition to form additional layer(s), thereby forming the low-density three-dimensional article. A low-density three-dimensional article prepared in accordance with the method is also provided.Type: GrantFiled: May 6, 2019Date of Patent: September 7, 2021Assignee: UT-Battelle, LLCInventors: Vlastimil Kunc, John M. Lindahl, Lonnie J. Love, Brian K. Post, Ahmed Hassen, Peng Liu, Thomas Zeke Sudbury