Patents by Inventor Weidong Song

Weidong Song 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).

  • Patent number: 12383975
    Abstract: A method of additive manufacturing a part having integrated passages is provided. In one aspect, the method includes forming a part having a near net shape by moving a friction stir tool to deposit a filler material in a predetermined formation. The tool can include a rotating spindle having a channel configured to hold the filler material. The method can include machining the near net shape part to form a plurality of grooves extending into a surface of the part, the plurality of grooves sized and shaped to each receive a tube. The method can include placing a tube into each of the plurality of grooves and moving the tool across the surface of the part and depositing additional material configured to secure the tubes within the plurality of grooves. The method can include machining the additional material deposited over the tubes to a predetermined shape.
    Type: Grant
    Filed: August 3, 2023
    Date of Patent: August 12, 2025
    Assignee: Blue Origin Manufacturing, LLC
    Inventor: Weidong Song
  • Publication number: 20250242431
    Abstract: A friction stir additive manufacturing device configured to join a first work-piece and a second work-piece is provided. In one aspect, the device includes a rotating spindle configured to deposit a filler material over a weld line as the device is advanced along an interface between the first work-piece and the second work-piece. The device also includes a deposition head configured to receive at least a portion of the spindle, the deposition head configured to remain stationary relative to the rotating spindle. The deposition head includes a first semi-cylindrical portion having an inner radius and an outer radius relative to a first axis, and a second semi-cylindrical portion having an inner radius and an outer radius relative to a second axis that is perpendicular to the first axis. The second semi-cylindrical portion can include a chamfered inner surface configured to define a weld profile.
    Type: Application
    Filed: March 3, 2025
    Publication date: July 31, 2025
    Inventors: Weidong Song, Michael Brennan, Alex Langenstein
  • Patent number: 12330258
    Abstract: Methods of ultrasonic drilling may be used to form perforated sheets by forming holes through a workpiece using a needle or needle array operatively coupled to an ultrasonic actuator. The needle is brought to repeatedly contact the surface of the workpiece at an ultrasonic operating frequency, thereby forming the hole through the workpiece. Such steps are repeated to form a plurality of holes in the workpiece, thereby forming a perforated sheet which may be used in an acoustic liner for noise attenuation. The workpiece may be heated while the holes are formed, via a remote heating unit that locally heats a portion of the workpiece.
    Type: Grant
    Filed: February 20, 2020
    Date of Patent: June 17, 2025
    Assignee: The Boeing Company
    Inventor: Weidong Song
  • Publication number: 20250187107
    Abstract: A friction stir additive welding screw is provided. In one aspect, the friction stir additive welding screw includes a first portion configured to be coupled to a friction stir additive welding device, and a second portion configured to penetrate a work-piece. The second portion includes a plurality of large threads, each large thread extending in a generally longitudinal direction. The second portion also includes a plurality of fine threads positioned along an edge of each large thread, and a plurality of teeth at a tip of second portion.
    Type: Application
    Filed: December 12, 2024
    Publication date: June 12, 2025
    Inventors: Weidong Song, Kareem Syed, W. Douglas Hartley, Zhi Tang, Kris Heitmeyer, Andrew Winnie, Kam To Law
  • Publication number: 20250187105
    Abstract: A friction stir additive manufacturing system configured to extrude a material is provided. In one aspect, the system includes a spindle configured to rotate about a central axis, the spindle including a conical portion having a plurality of threads at a deposition end of the spindle. The system also includes a housing configured to remain stationary relative to the spindle, the housing including a wire inlet extending through a side wall of the housing, an interior surface of the side wall defining a truncated cone terminating at a material exit, the truncated cone configured to receive the conical portion of the spindle. The system also includes a feeding system configured to feed a wire through the wire inlet and into a gap between the spindle and the truncated cone of the housing.
    Type: Application
    Filed: December 12, 2024
    Publication date: June 12, 2025
    Inventors: Weidong Song, W. Douglas Hartley
  • Publication number: 20250187108
    Abstract: A friction stir additive manufacturing system is provided. In one aspect, the system includes a spindle configured to rotate about a central axis, and a housing configured to receive at least a portion of the spindle, the housing configured to remain stationary relative to the spindle. The housing includes a wire inlet extending between an exterior surface of the housing and an interior surface of the housing, and a track extending from the wire inlet and partially around a circumference of an interior surface of the housing. The system also includes a feeding system configured to receive a wire from a roller and feed the wire through the wire inlet and into the track of the housing.
    Type: Application
    Filed: December 12, 2024
    Publication date: June 12, 2025
    Inventor: Weidong Song
  • Publication number: 20250187106
    Abstract: A friction stir additive welding device configured to join a first work-piece and second work-piece is provided. In one aspect, the device includes a nosecone having a sidewall extending from a first end to a second end, a channel extending from the first end to the second end along a longitudinal axis of the nosecone, and a screw positioned within the channel. The first end is configured to couple the nosecone to a robotic arm and the second end has a surface configured to be advanced along a weld line between the first and second work-pieces. A central axis of the screw defines an angle that is less than 90 degrees relative to a plane that is perpendicular to surfaces of the first and second work-pieces as the surface of the nosecone advances along the weld line.
    Type: Application
    Filed: December 12, 2024
    Publication date: June 12, 2025
    Inventors: Weidong Song, Kareem Syed, W. Douglas Hartley, Zhi Tang, Kris Heitmeyer, Andrew Winnie, Kam To Law
  • Publication number: 20250187104
    Abstract: A friction stir additive welding device configured to join a first work-piece and second work-piece is provided. In one aspect, the device includes a nosecone including a channel extending along a central axis and configured to receive a rotating screw. The device also includes a slot including a first opening in an outer sidewall of the nosecone, a second opening in a wall of the channel of the nosecone, and a passageway through the nosecone between the first opening and the second opening. The slot is configured to receive a portion of a structure positioned between the first work-piece and the second work-piece.
    Type: Application
    Filed: December 12, 2024
    Publication date: June 12, 2025
    Inventors: Weidong Song, Kareem Syed, W. Douglas Hartley, Zhi Tang, Kris Heitmeyer, Andrew Winnie, Kam To Law
  • Patent number: 12318987
    Abstract: Methods and an apparatus are presented. A bulk molding compound is consolidated by sending the bulk molding compound through a die breaker and an extrusion die of a consolidation system.
    Type: Grant
    Filed: May 5, 2022
    Date of Patent: June 3, 2025
    Assignee: The Boeing Company
    Inventor: Weidong Song
  • Publication number: 20250163869
    Abstract: Transpiration-cooled systems having permeable and non-permeable portions are provided. In one aspect, a nozzle for a rocket engine includes a non-permeable outer layer, a plurality of walls, a permeable layer, and a plurality of cooling channels. The non-permeable outer layer forms a predetermined shape of the nozzle and defines an interior space. The plurality of walls extend generally orthogonal to the non-permeable outer layer and into the interior space. The permeable layer is disposed between each set of adjacent walls of the plurality of walls. The permeable layer is spaced a distance from the non-permeable outer layer. The plurality of cooling channels are formed between the permeable layer, the non-permeable outer layer, and a set of adjacent walls of the plurality of walls. The plurality of cooling channels are configured to transport a fluid.
    Type: Application
    Filed: January 17, 2025
    Publication date: May 22, 2025
    Inventors: Weidong Song, Kutter Kupke, Alexander Twaites
  • Publication number: 20250163566
    Abstract: A kit for manufacturing a structure in space is provided. In one aspect, the kit includes an inflatable bladder having an internal wall configured to define an internal space of the structure when the bladder is inflated. The kit also includes a structural liner coupled to the internal wall of the inflatable bladder. The kit also includes one or more e-beam physical vapor deposition systems configured to be positioned within the internal space of the structure when the bladder is inflated. The one or more e-beam physical vapor deposition systems configured to form a metallic structural shell on the structural liner.
    Type: Application
    Filed: November 22, 2023
    Publication date: May 22, 2025
    Inventors: Weidong Song, Brent Sherwood
  • Publication number: 20250162063
    Abstract: A method of additive manufacturing a structure having integrated passages is provided. In one aspect, the method includes forming first and second parts, each part having a near net shape. The first and second parts are formed by moving a friction stir tool configured to deposit a filler material. An inner surface of each part can be machined to form a generally smooth surface. The first and the second parts are joined to form a structure. The structure is machined to form a generally smooth outer surface. The method includes machining a plurality of grooves extending into the generally smooth outer surface of the structure. A tube is placed into each of the plurality of grooves and a layer of material is deposited to secure the tubes within the plurality of grooves. The method can include machining the outer surface to a predetermined shape.
    Type: Application
    Filed: January 17, 2025
    Publication date: May 22, 2025
    Inventors: Michael L. Bailey, Weidong Song
  • Publication number: 20250135574
    Abstract: A method of joining a first work-piece to a second work-piece is provided. Each of the first work-piece and the second work-piece include a top surface, an opposed bottom surface, and a side surface connecting the top surface and the opposed bottom surface. In one aspect, the method includes positioning the side surface of the first work-piece adjacent to the side surface of the second work-piece, and advancing a friction stir additive manufacturing tool across the top surface of the first work-piece and the top surface of the second work-piece along a weld line between the first work-piece and the second work-piece. As the friction stir additive manufacturing tool advances along the weld line, a filler material is deposited along the weld line and into a plurality of through holes formed in either or both of the first work-piece and the second work-piece.
    Type: Application
    Filed: November 14, 2024
    Publication date: May 1, 2025
    Inventor: Weidong Song
  • Publication number: 20250127452
    Abstract: The disclosure relates to a lung function detection method, system and apparatus, and to a computer device and a storage medium. The method comprises: acquiring chest and abdomen surface point cloud data of a subject under test within a preset time period by means of a biological detection sensor; analyzing the chest and abdomen surface point cloud data, and determining lung ventilation change information of the subject under test; and according to the lung ventilation change information, determining a lung function detection result of the subject under test. The biological detection sensor is arranged within a preset range around the subject under test but does not come in contact with the subject under test.
    Type: Application
    Filed: March 24, 2023
    Publication date: April 24, 2025
    Inventors: Weidong SONG, Yi HUANG, Wei HU, Junjie LEI, Yan GONG
  • Publication number: 20250108941
    Abstract: Systems and methods for securing an upright rocket. The rocket may be on a moveable platform, such as a landing area of a ship. The rocket may land on the deck, and the system may include cables that surround the landing area. The cables may be tightened about the rocket after the rocket has landed in an upright position. The system may include poles that telescope upward, such that the cables may tighten about the upright rocket at various heights along the body of the rocket.
    Type: Application
    Filed: September 24, 2024
    Publication date: April 3, 2025
    Inventor: Weidong Song
  • Patent number: 12246392
    Abstract: A friction stir additive manufacturing device configured to join a first work-piece and a second work-piece is provided. In one aspect, the device includes a rotating spindle configured to deposit a filler material over a weld line as the device is advanced along an interface between the first work-piece and the second work-piece. The device also includes a deposition head configured to receive at least a portion of the spindle, the deposition head configured to remain stationary relative to the rotating spindle. The deposition head includes a first semi-cylindrical portion having an inner radius and an outer radius relative to a first axis, and a second semi-cylindrical portion having an inner radius and an outer radius relative to a second axis that is perpendicular to the first axis. The second semi-cylindrical portion can include a chamfered inner surface configured to define a weld profile.
    Type: Grant
    Filed: March 30, 2023
    Date of Patent: March 11, 2025
    Assignee: Blue Origin Manufacturing, LLC
    Inventors: Weidong Song, Michael Brennan, Alex Langenstein
  • Publication number: 20250041964
    Abstract: A method of additive manufacturing a structure having integrated passages is provided. In one aspect, the method includes forming first and second parts, each part having a near net shape. The first and second parts are formed by moving a friction stir tool configured to deposit a filler material. An inner surface of each part can be machined to form a generally smooth surface. The first and the second parts are joined to form a structure. The structure is machined to form a generally smooth outer surface. The method includes machining a plurality of grooves extending into the generally smooth outer surface of the structure. A tube is placed into each of the plurality of grooves and a layer of material is deposited to secure the tubes within the plurality of grooves. The method can include machining the outer surface to a predetermined shape.
    Type: Application
    Filed: August 3, 2023
    Publication date: February 6, 2025
    Inventors: Michael L. Bailey, Weidong Song
  • Publication number: 20250041963
    Abstract: A method of additive manufacturing a part having integrated passages is provided. In one aspect, the method includes forming a part having a near net shape by moving a friction stir tool to deposit a filler material in a predetermined formation. The tool can include a rotating spindle having a channel configured to hold the filler material. The method can include machining the near net shape part to form a plurality of grooves extending into a surface of the part, the plurality of grooves sized and shaped to each receive a tube. The method can include placing a tube into each of the plurality of grooves and moving the tool across the surface of the part and depositing additional material configured to secure the tubes within the plurality of grooves. The method can include machining the additional material deposited over the tubes to a predetermined shape.
    Type: Application
    Filed: August 3, 2023
    Publication date: February 6, 2025
    Inventor: Weidong Song
  • Publication number: 20250035071
    Abstract: Transpiration-cooled systems having permeable and non-permeable portions are provided. In one aspect, a nozzle for a rocket engine includes a non-permeable outer layer, a plurality of walls, a permeable layer, and a plurality of cooling channels. The non-permeable outer layer forms a predetermined shape of the nozzle and defines an interior space. The plurality of walls extend generally orthogonal to the non-permeable outer layer and into the interior space. The permeable layer is disposed between each set of adjacent walls of the plurality of walls. The permeable layer is spaced a distance from the non-permeable outer layer. The plurality of cooling channels are formed between the permeable layer, the non-permeable outer layer, and a set of adjacent walls of the plurality of walls. The plurality of cooling channels are configured to transport a fluid.
    Type: Application
    Filed: October 11, 2024
    Publication date: January 30, 2025
    Inventors: Weidong Song, Kutter Kupke, Alexander Twaites
  • Patent number: 12209559
    Abstract: Transpiration-cooled systems having permeable and non-permeable portions are provided. In one aspect, a nozzle for a rocket engine includes a non-permeable outer layer, a plurality of walls, a permeable layer, and a plurality of cooling channels. The non-permeable outer layer forms a predetermined shape of the nozzle and defines an interior space. The plurality of walls extend generally orthogonal to the non-permeable outer layer and into the interior space. The permeable layer is disposed between each set of adjacent walls of the plurality of walls. The permeable layer is spaced a distance from the non-permeable outer layer. The plurality of cooling channels are formed between the permeable layer, the non-permeable outer layer, and a set of adjacent walls of the plurality of walls. The plurality of cooling channels are configured to transport a fluid.
    Type: Grant
    Filed: December 20, 2023
    Date of Patent: January 28, 2025
    Assignee: Blue Origin, LLC
    Inventors: Weidong Song, Kutter Kupke, Alexander Twaites