Composite structures and methods of forming composite structures

A composite structure, comprising:

• a first component part, the first component part including:
• a first sheet of thermoplastic fiber reinforced material, wherein the first component part has an outside perimeter, wherein the outside perimeter of the first component part includes a least a first outside edge section and a second outside edge section, and wherein a first discontinuity is located between the first outside edge section of the first component part and the second outside edge section of the first component part;
• and
• a second component part, the second component part including:
• a second sheet of thermoplastic fiber reinforced material, wherein the second component part has an outside perimeter, wherein the outside perimeter of the second component part includes at least a first outside edge section and a second outside edge section, wherein a first discontinuity is located between the first outside edge section of the second component part and the second outside edge section of the second component part,
• wherein the first component part is joined to the second component part,
• wherein an interior volume is formed between at least a portion of the first component part and at least a portion of the second component part,
• wherein the first discontinuity of the first component part is adjacent the first discontinuity of the second component part to form a first aperture, and
• wherein the first component part further includes a third sheet of thermoplastic fiber reinforced material fused to the first sheet of thermoplastic fiber reinforced material, and
• wherein the second component part further includes a fourth sheet of thermoplastic fiber reinforced material fused to the second sheet of thermoplastic fiber reinforced material.

A composite panel, comprising:

• a first sheet, the first sheet including:
• a plurality of fibers;
• and
• a thermoplastic material, wherein the fibers are embedded in the thermoplastic material;
• and
• a second sheet, the second sheet including:
• a plurality of fibers;
• and
• a thermoplastic material, wherein the fibers are embedded in the thermoplastic material,
• wherein the first sheet is fused to the second sheet to form the composite panel,
• wherein the fibers of the first sheet are at a non-zero angle orientation with respect to at least most of the fibers of the second sheet,
• wherein the composite panel is shaped in three-dimensions, and
• wherein the composite panel includes at least a first aperture,
• wherein the composite panel has an outside perimeter with at least first, second, and third outside edge sections,
• wherein the first and second outside edge sections are separated from one another by a first discontinuity, and
• wherein the second and third outside edge sections are separated from one another by a second discontinuity.

A method of forming a composite structure, comprising:

• fusing a first plurality of sheets of a thermoplastic material containing a plurality of fibers to one another to form a multi-layered first composite panel, wherein the first plurality of sheets of the first composite panel include at least first and second sheets, wherein the plurality of fibers of the first sheet are unidirectionally aligned, wherein the plurality of fibers of the second sheet are oriented differently than the fibers of the first sheet, and wherein the first composite panel includes at least a first aperture;
• heating the first composite panel;
• and
• placing the heated first composite panel in a first portion of a first final mold, wherein the first composite panel is given a first final contour,
• wherein a first set of the plurality of fibers of the first sheet extend from a first edge section of the first sheet to a second edge section of the first sheet,
• prior to fusing the first plurality of sheets of a thermoplastic material containing a plurality of fibers to one another to form a multi-layered first composite panel, trimming the first sheet to define a third edge section,
• wherein trimming the first sheet to define the third edge section includes cutting the first set of the plurality of fibers of the first sheet to form an aperture such that after the trimming at least some of the fibers are separated into two segments,
• wherein a first one of the segments extends from the first edge section of the first sheet to the third edge section, and
• wherein a second one of the segments extends from the third edge section to the second edge section.

A method of forming a composite structure, comprising:

• fusing a first plurality of sheets of a thermoplastic material containing a plurality of fibers to one another to form a multi-layered first composite panel, wherein the first plurality of sheets of the first composite panel include at least first and second sheets, wherein the plurality of fibers of the first sheet are unidirectionally aligned, wherein the plurality of fibers of the second sheet are oriented differently than the fibers of the first sheet, and wherein the first composite panel includes at least a first aperture;
• heating the first composite panel;
• placing the heated first composite panel in a first portion of a first final mold, wherein the first composite panel is given a first final contour;
• fusing a second plurality of sheets of the thermoplastic material containing a plurality of fibers to one another to form a multi-layered second composite panel, wherein the second plurality of sheets of the second composite panel include at least third and fourth sheets, wherein the plurality of fibers of the third sheet are unidirectionally aligned, wherein the plurality of fibers of the fourth sheet are oriented differently than the fibers of the third sheet, and wherein the second composite panel includes at least a second aperture;
• heating the second composite panel;
• placing the heated second composite panel in a second portion of the first final mold, wherein the second composite panel is given a second final contour;
• and
• fusing the second composite panel to the first composite panel to form the composite structure.