Thermoplastic aerostructure with localized ply isolation and method for forming aerostructure

A composite aerostructure, comprising:

• a plurality of longitudinally elongated spars, each of which comprises an upper element having a layer of unidirectional or woven carbon fiber reinforced thermoplastic material forming a weld zone;
• and
• a plurality of elongated ribs interconnected with the plurality of spars to from a grid, wherein each rib comprises an upper element having a layer of unidirectional or woven carbon fiber reinforced thermoplastic material forming a weld zone;
• a composite skin connected with the grid of spars and ribs, comprising:
• a first ply of carbon fiber reinforced thermoplastic material, wherein the carbon fibers are oriented in a first direction;
• a second ply of carbon fiber reinforced thermoplastic material, wherein the carbon fibers are oriented in the first direction and the first ply overlies and is directly connected to the second ply;
• a third ply of carbon fiber reinforced thermoplastic material, wherein the carbon fibers are oriented in a second direction transverse the first direction;
• a fourth ply of carbon fiber reinforced thermoplastic material, wherein the carbon fibers are oriented in the second direction and the third ply overlies and is directly connected to the fourth ply;
• a fifth ply of carbon fiber reinforced thermoplastic material, wherein the carbon fibers are oriented transverse the carbon fibers in the upper elements of the spars and the ribs;
• a plurality of elongated insulating elements formed of electrically insulating material, wherein the insulating elements each have a length and a width and at least a plurality of the insulating elements have a length that is substantially greater the width;
• and wherein the insulating elements form a grid configured substantially similarly to the grid formed by the ribs and spars so that the insulating elements overlie the upper elements of the spars and ribs, wherein the grid of insulating elements is disposed between the second layer and the third layer.