Back to results
US 11,993,388 B2Granted
Corrugated stiffening devices utilizing peaks and valleys and methods of manufacture
AssigneeRohr, Inc.
InventorsJennifer Davis, Nathaniel M. Gray
Life of this patent
Estimating the term…
Abstract
A method may comprise: laying up a first plurality of plies of material comprising thermoplastic resin and fiber to form an inner skin preform, the inner skin preform being a continuous sheet including alternating peaks and valleys; laying up a second plurality of plies of material comprising thermoplastic resin and fiber to form an outer skin preform; and joining the inner skin preform to the outer skin preform.
Claims20
A method for forming a thermoplastic panel, comprising:
- laying up a first plurality of plies of material comprising thermoplastic resin and fiber on a first layup tool to form an inner skin preform, the inner skin preform being a continuous sheet including alternating peaks and valleys;
- laying up a second plurality of plies of material comprising thermoplastic resin and fiber on a second layup tool to form an outer skin preform, the outer skin preform including an arcuate shape, an outer surface being contoured in a longitudinal direction;
- after the laying up the first plurality of plies of material and the second plurality of plies of material, assembling the inner skin preform with the outer skin preform to form an assembled preform, the assembled preform disposed on the second layup tool with the valleys disposed on an inner surface of the outer skin preform and each peak in the alternating peaks and valleys protruding away from the inner surface of the outer skin preform, each peak and the inner surface defining a gap therebetween;
- disposing the assembled preform in an autoclave;
- and
- joining, by heating and pressurizing via the autoclave, the valleys of the inner skin preform to the outer skin preform to form a stiffening structure for the thermoplastic panel, wherein the valleys of the inner skin preform conform to the arcuate shape of the outer skin preform.
3 more elements
A method of manufacturing a thermoplastic panel, the method comprising:
- assembling an inner skin preform and an outer skin preform to form an assembled preform, the inner skin preform having a first contour including alternating peaks and valleys prior to the assembling, the valleys of the inner skin preform in contact with an inner surface of the outer skin preform, the outer skin preform including an arcuate shape, an outer surface of the outer skin preform being contoured in a longitudinal direction, each peak and the inner surface defining a gap therebetween;
- disposing the assembled preform in an autoclave;
- applying localized heat and pressure, via the autoclave, to joining locations coinciding with an interface between the valleys of the inner skin preform and the outer skin preform;
- and
- consolidating the valleys of the inner skin preform to the outer skin preform to form the thermoplastic panel, the thermoplastic panel including a stiffening structure formed from the inner skin preform, wherein the valleys of the inner skin preform conform to the arcuate shape of the outer skin preform.
2 more elements
Dependencies are inferred from the claim text.