Scott R Garrett

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through the first hollow tube so that it follows the pathway in the x-y material formed by the rod which is now withdrawn downwardly through the aperture in the bottom wall.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:

7217453, May 15, 2007

Filed:

Dec 23, 2003

Appl. No.:

10/744630

Inventors:

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

Assignee:

Ebert Compoistes Corporation - Chula Visa CA

International Classification:

D04H 1/00
B32B 27/04

US Classification:

4282921, 4282981

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:

7387147, Jun 17, 2008

Filed:

Sep 11, 2006

Appl. No.:

11/530859

Inventors:

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

Assignee:

Ebert Composites Corporation - Chula Vista CA

International Classification:

B32B 37/00

US Classification:

156433, 156 92, 156148, 156441

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:

7690179, Apr 6, 2010

Filed:

Jun 29, 2007

Appl. No.:

11/771919

Inventors:

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

Assignee:

Ebert Composites Corporation - Chula Vista CA

International Classification:

D06B 23/08

US Classification:

57 1UN, 57 91

Abstract:

A method of maintaining the location of a fiber doff inner-diameter-tow at a point of payout within a constant inertial reference frame includes providing a flat fiber tow payout system with a center-pull doff of flat fiber tow that pays out at a point of payout along an inner diameter of the center-pull doff with rotation of the center-pull doff about a vertically oriented axis of rotation, the flat fiber tow payout system including a constant inertial reference frame for payout of the flat fiber tow along the inner diameter of the center-pull doff without twisting the flat fiber tow; and accelerating and stopping rotation of the center-pull doff with the flat fiber tow payout system so as to maintain payout of the flat fiber tow along the inner diameter of the center-pull doff in the constant inertial reference frame, preventing twisting of the flat fiber tow.

US Patent:

7785693, Aug 31, 2010

Filed:

Dec 11, 2008

Appl. No.:

12/333155

Inventors:

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

Assignee:

Ebert Composites Corporation - Chula Vista CA

International Classification:

B32B 3/06

US Classification:

428 99, 428102, 4282921, 4283179

Abstract:

A composite laminate structure includes a first skin; a second skin; a core between the first skin and the second skin, the core including adjacent core sections and a Z-Y partition separating the adjacent core sections; and a plurality of distinct groupings of Z-axis fibers that extend from the first skin to the second skin through the adjacent core sections and the Z-Y partition separating the adjacent core sections.

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.