Thomas A Carstensen

US Patent:

6739861, May 25, 2004

Filed:

Nov 26, 2001

Appl. No.:

09/995393

Inventors:

David M. Cournoyer - Seymour CT
Neil W. Cawthra - Shelton CT
Thomas A. Carstensen - Shelton CT
Christian A. Rogg - New Milford CT
Michael G. Osiecki - Oxford CT

Assignee:

Sikorsky Aircraft Corporation - Stratford CT

International Classification:

B29C 3338

US Classification:

425520, 425389, 249135

Abstract:

The composite molding apparatus includes a rigid base member and a complementary semi-rigid mold member or âblack bagâ caul plate having a sieve member formed therein. The sieve member layer of the semi-rigid mold member engages pins which extend from the sandwich core to limit penetration into the semi-rigid mold member to a predetermined depth. The semi-rigid mold member is supported relative to the rigid mold member by the pins to provide uniform pressure transfer to the composite article during a high pressure co-cure molding process without crushing the sandwich core.

US Patent:

8327738, Dec 11, 2012

Filed:

Nov 7, 2003

Appl. No.:

10/703372

Inventors:

Geoffrey Clive Robert Davis - Madison CT, US
Thomas Arthur Carstensen - Shelton CT, US
Stephen Carter Varanay - Guilford CT, US

Assignee:

Sikorsky Aircraft Corporation - Stratford CT

International Classification:

F16H 57/02
F16H 57/04
F16H 61/00

US Classification:

74606R, 343872, 298896, 416169 R, 416107, 264258, 89 3602, 244 1711

Abstract:

A composite transmission housing includes resin transfer molding or vacuum assisted resin transfer molding manufacturing processes combined with discontinuous fiber preforms. The preforms are assembled in a prepared injection and cure mold with additional details and fillers. The preforms are constructed such that the preforms are assembled into the mold in a specific order to assure proper arrangement. Using a combination of vacuum and pressure, a resin is injected into the mold to completely infuse the assembled preforms. At completion, the mold is heated to the resin cure temperature and held at this temperature for sufficient time to insure complete cure.

US Patent:

20040121138, Jun 24, 2004

Filed:

Dec 20, 2002

Appl. No.:

10/325238

Inventors:

Thomas Carstensen - Shelton CT, US

International Classification:

B32B003/26
B32B005/24
D21H011/00
D21H013/00

US Classification:

428/304400, 428/311110, 428/311510

Abstract:

A composite material has a foam core having first and second faces. A plurality of fibrous pins have first end portions protruding from the core first face. A first face sheet is secured to the core first face. The first face sheet comprises, in major part, one or more non-woven, non random, fiber layers. The pin first end portions protrude into the first face sheet.

US Patent:

20070193146, Aug 23, 2007

Filed:

Jan 26, 2007

Appl. No.:

11/627491

Inventors:

Thomas A. Carstensen - Shelton CT, US
David M. Cournoyer - Seymour CT, US
Dan Ursenbach - Hamden CT, US

Assignee:

SIKORSKY AIRCRAFT CORPORATION - Stratford CT

International Classification:

E04B 1/00

US Classification:

52268

Abstract:

An aircraft floor system includes a composite panel which generally includes an inboard layer, an inboard interlock layer, a core layer, an outboard interlock layer and an outboard layer. The advanced sandwich core material may include K-Cor™ or X-Cor™ which is pinned through at least one ply of dry composite reinforcement to provide a mechanical lock between the pins and an inboard and outboard interlock layer. Bonding of the locked-in ply with the inboard and outboard results in improved structural performance and damage tolerance.

US Patent:

20110011518, Jan 20, 2011

Filed:

Jul 26, 2006

Appl. No.:

11/493052

Inventors:

Thomas Carstensen - Shelton CT, US
William V. Forster - Oxford CT, US
Christian A. Rogg - New Milford CT, US

International Classification:

B32B 38/04
B29C 65/00
B32B 5/00

US Classification:

156 91, 156 60, 156256, 156252, 4281951, 428201

Abstract:

A thermoplastic matrix airframe structure section includes a multitude of thermoplastic matrix frame members and a multitude of thermoplastic matrix beam members which form a substructure, which receives a thermoplastic matrix inner cap grid structure, a thermoplastic matrix outer cap grid structure, and a thermoplastic matrix skin which are in-situ co-bonded to the substructure to significantly strengthen and unify the substructure.

US Patent:

20130055881, Mar 7, 2013

Filed:

Sep 2, 2011

Appl. No.:

13/224677

Inventors:

Connie E. Bird - Rocky Hill CT, US
Alan R. Goodworth - Oxford CT, US
Thomas A. Carstensen - Shelton CT, US
Gary Hamilton - Middletown CT, US

International Classification:

F41H 5/04
B23P 11/00
B32B 3/06
B64D 7/00
B32B 5/16

US Classification:

89 3602, 4282921, 428 99, 29428, 89904, 89914, 89917, 89912

Abstract:

An armor panel includes a multiple of pins which penetrate a first skin, a high molecular weight polyethylene fiber composite material layer and a second skin which integrates ballistic protection into load bearing structure.

US Patent:

20130340601, Dec 26, 2013

Filed:

Apr 16, 2007

Appl. No.:

11/735594

Inventors:

William A. Townsend - Stratford CT, US
Thomas A. Carstensen - Shelton CT, US
Connie E. Bird - Rocky Hill CT, US

International Classification:

B64D 7/00
F41H 5/04

US Classification:

89 3602

Abstract:

An armor system which integrates ballistic protection into load bearing structure. Each armored panel is manufactured as a sandwich structure having a multiple of layers including a hard ballistic material layer of a Ceramic/CMC hybrid armor material capable of defeating high velocity Armor Piercing projectiles.

US Patent:

53541952, Oct 11, 1994

Filed:

Dec 23, 1992

Appl. No.:

7/995437

Inventors:

Alex C. Dublinski - Northford CT
Thomas A. Carstensen - Shelton CT
Philip J. Ramey - Milford CT

Assignee:

United Technologies Corporation - Hartford CT

International Classification:

B29C 3318

US Classification:

425504

Abstract:

A composite molding apparatus for high pressure co-cure molding of lightweight honeycomb core composite articles having ramped surfaces utilizing low total density, stabilized ramped honeycomb cores. The composite molding apparatus is a semi-rigid molding assembly that includes a rigid base member and a complementary semi-rigid mold member that is formed from a combination of layers of fiber-reinforced elastomeric material and unreinforced elastomeric material. The semi-rigid mold member further includes internal rigid reinforcement inserts formed from a structurally rigid material and having a configuration that matches the configuration of the ramped surfaces of the honeycomb composite article. The rigid reinforcement inserts are interleaved between the layers of fiber-reinforced elastomeric material and/or unreinforced elastomeric material forming the semi-rigid mold member. The rigid reinforcement inserts of the semi-rigid mold member provide symmetric pressure distribution over the ramped surfaces of the honeycomb core and the overlayed composite prepregs during the high pressure co-cure process.