公开(公告)号：US20240253299A1

公开(公告)日：2024-08-01

申请号：US18162152

申请日：2023-01-31

Applicant: NORTHROP GRUMMAN SYSTEMS CORPORATION

Inventor： Chesley Lane ,  Steven J. Floyd ,  Talbot P. Thrasher ,  Timothy R. Stone ,  Vernon M. Benson

IPC: B29C64/147 ,  B29C64/188 ,  B29C64/205

CPC classification number: B29C64/147 ,  B29C64/188 ,  B29C64/205 ,  B29K2307/04 ,  B29K2309/08 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/00

Abstract: A machine for manufacturing tube elements comprised of tape strips. The machine includes a shaft, a disk mounted to one end of the shaft, a motor coupled to an opposite end of the shaft, and a plate mounted to the shaft. The plate includes a plurality of spools mounted to the plate, where a separate one of the strips is wound on each spool. In one embodiment, the machine further includes a rail positioned adjacent to the disk, a slide slidably secured to the rail and including an end support configured to hold ends of the tape strips, and an indexer configured to pull the slide on the rail away from the disk. The tape strips are unwound from the spools when the indexer pulls the slide in a manner so that the tape strips ride in a spaced apart manner around the disk to form the tube element.

公开(公告)号：US20240083823A1

公开(公告)日：2024-03-14

申请号：US18508839

申请日：2023-11-14

Applicant: Northrop Grumman Systems Corporation

Inventor： Talbot P. Thrasher ,  Timothy E. Dominick

IPC: C04B35/83 ,  B29C64/118 ,  B29C64/30 ,  B33Y10/00 ,  B33Y40/00 ,  B33Y80/00 ,  C04B35/622 ,  C04B35/628 ,  C04B35/64

CPC classification number: C04B35/83 ,  B29C64/118 ,  B29C64/30 ,  B33Y10/00 ,  B33Y40/00 ,  B33Y80/00 ,  C04B35/6224 ,  C04B35/62272 ,  C04B35/62844 ,  C04B35/62886 ,  C04B35/64 ,  B29K2071/00

Abstract: Methods for fabricating high-temperature composite structures (e.g., structures comprising carbon-carbon composite materials or ceramic composite matrix (CMC) materials and configured for use at temperature at or exceeding about 2000° F. (1093° C.)) include forming precursor structures by additive manufacturing (“AM”) (e.g., “3D printing”) with a filament drawn from a spool. The precursor structures are exposed to high temperatures to pyrolyze a precursor matric material of the initial 3D printed structure. A liquid resin is used to impregnate the pyrolyzed structure, to densify the structure into a near-net final shape. Use of expensive and time-consuming molds and post-processing machining may be avoided. Large, unitary, integrally formed parts conducive for use in high-temperature environments may be formed using the methods of the disclosure.

公开(公告)号：US12172368B2

公开(公告)日：2024-12-24

申请号：US18162152

申请日：2023-01-31

Applicant: NORTHROP GRUMMAN SYSTEMS CORPORATION

Inventor： Chesley Lane ,  Steven J. Floyd ,  Talbot P. Thrasher ,  Timothy R. Stone ,  Vernon M. Benson

IPC: B29C64/147 ,  B29C64/188 ,  B29C64/205 ,  B29K307/04 ,  B29K309/08 ,  B33Y10/00 ,  B33Y30/00 ,  B33Y40/00

Abstract: A machine for manufacturing tube elements comprised of tape strips. The machine includes a shaft, a disk mounted to one end of the shaft, a motor coupled to an opposite end of the shaft, and a plate mounted to the shaft. The plate includes a plurality of spools mounted to the plate, where a separate one of the strips is wound on each spool. In one embodiment, the machine further includes a rail positioned adjacent to the disk, a slide slidably secured to the rail and including an end support configured to hold ends of the tape strips, and an indexer configured to pull the slide on the rail away from the disk. The tape strips are unwound from the spools when the indexer pulls the slide in a manner so that the tape strips ride in a spaced apart manner around the disk to form the tube element.

公开(公告)号：US11701816B2

公开(公告)日：2023-07-18

申请号：US17122343

申请日：2020-12-15

Applicant: NORTHROP GRUMMAN SYSTEMS CORPORATION

Inventor： Eric G. Barnes ,  Talbot P. Thrasher ,  Timothy E. Dominick

IPC: B29C64/118 ,  B29C64/188 ,  B33Y40/20 ,  B33Y10/00 ,  B33Y70/10 ,  B29K101/12 ,  B29K307/04

CPC classification number: B29C64/118 ,  B29C64/188 ,  B33Y40/20 ,  B29K2101/12 ,  B29K2307/04 ,  B33Y10/00 ,  B33Y70/10

Abstract: A method for fabricating a composite part using a 3D printing machine. The method includes forming the part by depositing a plurality of part layers in a consecutive manner on top of each other where each layer is deposited by laying down rows of filaments made of a thermoplastic composite material. Reinforcing Z-pins are then inserted through the part layers to provide reinforcement of the part in the Z-direction. A plurality of additional part layers are deposited in a consecutive manner on top of each other on the part layers including the reinforcing Z-pins where each additional part layer is also deposited by laying down rows of filaments made of a thermoplastic composite material. Reinforcing Z-pins are also inserted through the additional part layers to provide reinforcement of the part in the Z-direction.

公开(公告)号：US11135763B2

公开(公告)日：2021-10-05

申请号：US15969005

申请日：2018-05-02

Applicant: Northrop Grumman Systems Corporation

Inventor： Peter A. Beyerle ,  Kenneth Johnson ,  Brett A. Poor ,  Talbot P. Thrasher

IPC: B32B3/12 ,  B29C64/118 ,  B33Y10/00 ,  B33Y70/00 ,  H01Q17/00 ,  B33Y80/00 ,  B29K105/16

Abstract: An assembly formed by additive manufacturing comprises a top face sheet, a bottom face sheet, and a core structure between the top face sheet and the bottom face sheet, the core structure comprising a plurality of cells, wherein structural elements of the core structure defining the plurality of cells exhibit at least one electrical property in at least one direction varying from at least one electrical property in a second, different direction and at least one structural property in at least one direction varying from at least one structural property in a second, different direction, wherein at least a portion of the structural elements comprises a radar absorbing structure, the structural elements comprising a matrix material and at least one additive dispersed in or on the matrix material. Related radar absorbing structures and related methods of fabricating the radar absorbing structures are also disclosed.

公开(公告)号：US20220184880A1

公开(公告)日：2022-06-16

申请号：US17122343

申请日：2020-12-15

Applicant: NORTHROP GRUMMAN SYSTEMS CORPORATION

Inventor： Eric G. Barnes ,  Talbot P. Thrasher ,  Timothy E. Dominick

IPC: B29C64/118 ,  B29C64/188 ,  B33Y40/20

Abstract: A method for fabricating a composite part using a 3D printing machine. The method includes forming the part by depositing a plurality of part layers in a consecutive manner on top of each other where each layer is deposited by laying down rows of filaments made of a thermoplastic composite material. Reinforcing Z-pins are then inserted through the part layers to provide reinforcement of the part in the Z-direction. A plurality of additional part layers are deposited in a consecutive manner on top of each other on the part layers including the reinforcing Z-pins where each additional part layer is also deposited by laying down rows of filaments made of a thermoplastic composite material. Reinforcing Z-pins are also inserted through the additional part layers to provide reinforcement of the part in the Z-direction.

公开(公告)号：US11814324B2

公开(公告)日：2023-11-14

申请号：US16516104

申请日：2019-07-18

Applicant: Northrop Grumman Systems Corporation

Inventor： Talbot P. Thrasher ,  Timothy E. Dominick

IPC: C04B35/83 ,  B33Y10/00 ,  B33Y40/00 ,  B33Y80/00 ,  B29C64/118 ,  B29C64/30 ,  C04B35/622 ,  C04B35/628 ,  C04B35/64 ,  B29K71/00 ,  B29K81/00

CPC classification number: C04B35/83 ,  B29C64/118 ,  B29C64/30 ,  B33Y10/00 ,  B33Y40/00 ,  B33Y80/00 ,  C04B35/6224 ,  C04B35/62272 ,  C04B35/62844 ,  C04B35/62886 ,  C04B35/64 ,  B29K2071/00 ,  B29K2081/04 ,  C04B2235/422 ,  C04B2235/5232 ,  C04B2235/5248 ,  C04B2235/5252 ,  C04B2235/6026 ,  C04B2235/616 ,  C04B2235/656

Abstract: Methods for fabricating high-temperature composite structures (e.g., structures comprising carbon-carbon composite materials or ceramic composite matrix (CMC) materials and configured for use at temperature at or exceeding about 2000° F. (1093° C.)) include forming precursor structures by additive manufacturing (“AM”) (e.g., “3D printing”). The precursor structures are exposed to high temperatures to pyrolyze a precursor matric material of the initial 3D printed structure. A liquid resin is used to impregnate the pyrolyzed structure, to densify the structure into a near-net final shape. Use of expensive and time-consuming molds and post-processing machining may be avoided. Large, unitary, integrally formed parts conducive for use in high-temperature environments may be formed using the methods of the disclosure.