James David Hook

US Patent:

6645333, Nov 11, 2003

Filed:

Aug 2, 2001

Appl. No.:

09/922053

Inventors:

David W. Johnson - San Diego CA
Scott A Garrett - San Diego CA
James M. Hook - Alpine CA
Steven G. Moyers - Jamul CA

Assignee:

Ebert Composites Corporation - Chula Vista CA

International Classification:

B32B 3100

US Classification:

156 92, 159 91, 159148

Abstract:

A method of inserting z-axis reinforcing fibers into a multi-layer composite laminate. Layers of material made up of z-axis fiber and y-axis fibers are automatically transported into a z-fiber deposition machine having a housing with upper and lower surfaces. Z-axis apertures are formed in the respective upper and lower surfaces. An elongated solid rod having a tapered front tip is aligned in close proximity to the aperture n the bottom surface. The rod is first rotated by a motor and then actuated upwardly completely through the thickness of the layer of x-y material by an actuator. A first hollow tube having a z-axis is axially aligned with the aperture in the top surface and a fiber bundle is threaded downwardly through a first hollow tube to a position adjacent its bottom end. The z-fiber deposition machine has structure to feed a predetermined length of the fiber bundle downwardly through the first hollow tube so that it follows the pathway in the x-y material formed by the rod which is now withdrawn downwardly through the aperture in the bottom wall. The z-axis fiber is thus deposited into the x-y material.

US Patent:

6676785, Jan 13, 2004

Filed:

Nov 19, 2001

Appl. No.:

10/059956

Inventors:

David W. Johnson - San Diego CA
James M. Hook - Alpine CA
Scott A. Garrett - San Diego CA
Steven G. Moyers - Jamul CA

Assignee:

Ebert Composites Corporation - Chula Vista CA

International Classification:

B32B 3100

US Classification:

156 92, 156 91, 156166, 2952507, 411904

Abstract:

A method and apparatus for forming an improved pultruded and clinched Z-axis fiber reinforced composite laminate structure. The upper and lower skins and the core are pulled automatically through tooling where the skin material is wetted-out with resin and the entire composite laminate is preformed in nearly its final thickness. The preformed composite laminate continues to be pulled into an automatic 3-dimensional Z-axis fiber deposition machine that deposits âgroupings of fiber filamentsâ at multiple locations normal to the plane of the composite laminate structure and cuts each individual grouping such that an extension of each âgrouping of fiber filamentsâ remains above the upper skin and below the lower skin. The preformed composite laminate then continues to be pulled into a secondary wet-out station. Next the preformed composite laminate travels into a pultrusion die where the extended âgroupings of fiber filamentsâ are all bent over above the top skin and below the bottom skin producing a superior clinched Z-axis fiber reinforcement as a composite laminate continues to be pulled, catalyzed, and cured at the back section of the pultrusion die.

US Patent:

7105071, Sep 12, 2006

Filed:

Nov 10, 2003

Appl. No.:

10/705047

Inventors:

David W. Johnson - San Diego CA, US
Scott A. Garrett - San Diego CA, US
James M. Hook - Alpine CA, US
Stephen G. Moyers - Jamul CA, US

Assignee:

Ebert Composites Corporation - Chula Vista CA

International Classification:

B32B 37/00

US Classification:

156 92, 156 91, 156148

Abstract:

A method of inserting z-axis reinforcing fibers into a multi-layer composite laminate. Layers of material made up of z-axis fiber and y-axis fibers are automatically transported into a z-fiber deposition machine having a housing with upper and lower surfaces. Z-axis apertures are formed in the respective upper and lower surfaces. An elongated solid rod having a tapered front tip is aligned in close proximity to the aperture in the bottom surface. The rod is first rotated by a motor and then actuated upwardly completely through the thickness of the layer of x-y material by an actuator. A first hollow tube having a z-axis is axially aligned with the aperture in the top surface and a fiber bundle is threaded downwardly through a first hollow tube to a position adjacent its bottom end. The z-fiber deposition machine has structure to feed a predetermined length of the fiber bundle downwardly through the first hollow tube so that it follows the pathway in the x-y material formed by the rod which is now withdrawn downwardly through the aperture in the bottom wall. The z-axis fiber is thus deposited into the x-y material.

US Patent:

7846528, Dec 7, 2010

Filed:

May 7, 2007

Appl. No.:

11/745350

Inventors:

David W. Johnson - San Diego CA, US
Scott A. Garrett - San Diego CA, US
Stephen G. Moyers - Jamul CA, US
James M. Hook - Alpine CA, US

Assignee:

Ebert Composites Corporation - Chula Vista CA

International Classification:

B32B 7/00

US Classification:

428119, 4282981, 428 71

Abstract:

A method and apparatus for forming an improved pultruded and clinched Z-axis fiber reinforced composite laminate structure. The upper and lower skins and the core are pulled automatically through tooling where the skin material is wetted-out with resin and the entire composite laminate is preformed in nearly its final thickness. The preformed composite laminate continues to be pulled into an automatic 3-dimensional Z-axis fiber deposition machine that deposits “groupings of fiber filaments” at multiple locations normal to the plane of the composite laminate structure and cuts each individual grouping such that an extension of each “grouping of fiber filaments” remains above the upper skin and below the lower skin. The preformed composite laminate then continues to be pulled into a secondary wet-out station. Next the preformed composite laminate travels into a pultrusion die where the extended “groupings of fiber filaments” are all bent over above the top skin and below the bottom skin producing a superior clinched Z-axis fiber reinforcement as the composite laminate continues to be pulled, catalyzed, and cured at the back section of the pultrusion die.

US Patent:

8002919, Aug 23, 2011

Filed:

Jun 16, 2008

Appl. No.:

12/140121

Inventors:

David W. Johnson - San Diego CA, US
Scott A. Garrett - San Diego CA, US
James H. Hook - Alpine CA, US
Stephen G. Moyers - Jamul CA, US

Assignee:

Ebert Composites Corporation - Chula Vista CA

International Classification:

B32B 37/00

US Classification:

156 91, 156 92, 156148

Abstract:

A method of inserting z-axis reinforcing fibers into a multi-layer composite laminate. Layers of material made up of z-axis fiber and y-axis fibers are automatically transported into a z-fiber deposition machine having a housing with upper and lower surfaces. Z-axis apertures are formed in the respective upper and lower surfaces. An elongated solid rod having a tapered front tip is aligned in close proximity to the aperture in the bottom surface. The rod is first rotated by a motor and then actuated upwardly completely through the thickness of the layer of x-y material by an actuator. A first hollow tube having a z-axis is axially aligned with the aperture in the top surface and a fiber bundle is threaded downwardly through a first hollow tube to a position adjacent its bottom end. The z-fiber deposition machine has structure to feed a predetermined length of the fiber bundle downwardly through the first hollow tube so that it follows the pathway in the x-y material formed by the rod which is now withdrawn downwardly through the aperture in the bottom wall. The z-axis fiber is thus deposited into the x-y material.

US Patent:

8172171, May 8, 2012

Filed:

Jan 5, 2011

Appl. No.:

12/984857

Inventors:

David W. Johnson - San Diego CA, US
Scott G. Moyers - San Diego CA, US
James M. Hook - Alpine CA, US

Assignee:

Ebert Composites Corporation - Chula Vista CA

International Classification:

B65H 75/24

US Classification:

2425736

Abstract:

An adjustable doff core device for installation in the hollow center of a center-pull doff has a tubular core with a fixed internal diameter configured for engagement on a processor configured to dispense material from the outside of a doff. An adjustable outer press bar portion is adjustably mounted on the outside of the tubular core by an adjustment mechanism and is movable between an inner, contracted position and outwardly expanded positions spaced outwardly from the tubular core to define an adjustable outer diameter of the device. The press bar portion is configured for substantially non-slip engagement with an inner diameter of a hollow center-pull doff. A locking device releasably locks the press bar portion in a selected adjusted position.

US Patent:

8272188, Sep 25, 2012

Filed:

Dec 7, 2010

Appl. No.:

12/962046

Inventors:

David W. Johnson - San Diego CA, US
Scott A. Garrett - San Diego CA, US
Stephen G. Moyers - Jamul CA, US
James M. Hook - Alpine CA, US

Assignee:

Ebert Composites Corporation - Chula Vista CA

International Classification:

E04C 2/54

US Classification:

527821, 525921, 428223, 428119

Abstract:

A composite laminate structure includes a first skin; a second skin; and a plurality of distinct groupings of Z-axis fibers that extend from the first skin to the second skin, wherein the Z-axis fibers include opposite ends respectively terminating at and integrated into the first skin and the second skin.

US Patent:

20040137231, Jul 15, 2004

Filed:

Dec 23, 2003

Appl. No.:

10/744630

Inventors:

David Johnson - San Diego CA, US
Scott Garrett - San Diego CA, US
Stephen Moyers - Jamul CA, US
James Hook - Alpine CA, US

Assignee:

Ebert Composites Corporation

International Classification:

B32B009/04

US Classification:

428/411100

Abstract:

A method and apparatus for forming an improved pultruded and clinched Z-axis fiber reinforced composite laminate structure. The upper and lower skins and the core are pulled automatically through tooling where the skin material is wetted-out with resin and the entire composite laminate is preformed in nearly its final thickness. The preformed composite laminate continues to be pulled into an automatic 3-dimensional Z-axis fiber deposition machine that deposits “groupings of fiber filaments” at multiple locations normal to the plane of the composite laminate structure and cuts each individual grouping such that a extension of each “grouping of fiber filaments” remains above the upper skin and below the lower skin. The preformed composite laminate then continues to be pulled into a secondary wet-out station. Next the preformed composite laminate travels into a pultrusion die where the extended “groupings of fiber filaments” are all bent over above the top skin and below the bottom skin producing a superior clinched Z-axis fiber reinforcement as the composite laminate continues to be pulled, catalyzed, and cured at the back section of the pultrusion die. The composite laminate continues to be pulled by grippers that then feed it into a gantry CNC machine that is synchronous with the pull speed of the grippers and where computerized machining, drilling, and cutting operations take place. This entire method is accomplished automatically without the need for human operators.