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US 2025/0033756 A1Published application
Thermoplastic composite structure and methods for forming
AssigneeRohr, Inc.
InventorsShyan Bob Shen, Michael van Tooren, Daniel O. Ursenbach, Jeffrey D. Woods
Life of this patent
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Abstract
A method is provided during which a thermoplastic rib is arranged with a thermoplastic spar. A first flange of the thermoplastic rib is abutted against the thermoplastic spar. The first flange of the thermoplastic rib is ultrasonic welded to the thermoplastic spar using a tilted ultrasonic horn. A centerline of the tilted ultrasonic horn is angularly offset from the first flange of the thermoplastic rib by an acute angle during the ultrasonic welding.
Claims20
A method, comprising:
- arranging a thermoplastic rib with a thermoplastic spar, a first flange of the thermoplastic rib abutted against the thermoplastic spar;
- and
- ultrasonic welding the first flange of the thermoplastic rib to the thermoplastic spar using a tilted ultrasonic horn, a centerline of the tilted ultrasonic horn angularly offset from the first flange of the thermoplastic rib by an acute angle during the ultrasonic welding.
A method, comprising:
- forming a thermoplastic frame, the forming of the thermoplastic frame comprising disposing a flange of a rib in a channel of a spar, and ultrasonic welding the flange to the spar;
- ultrasonic welding a first thermoplastic skin to a first side of the thermoplastic frame;
- and
- ultrasonic welding a second thermoplastic skin to a second side of the thermoplastic frame;
- wherein at least the thermoplastic frame ultrasonic welded to the first thermoplastic skin and the second thermoplastic skin forms an aircraft structure.
2 more elements
An aircraft structure, comprising:
- a frame including a first thermoplastic spar, a second thermoplastic spar and a plurality of thermoplastic ribs arranged laterally between and longitudinally along the first thermoplastic spar and the second thermoplastic spar, each of the plurality of thermoplastic ribs welded to the first thermoplastic spar and the second thermoplastic spar;
- a first thermoplastic skin welded to the frame at a first side of the frame;
- and
- a second thermoplastic skin welded to the frame at a second side of the frame which is opposite the first side of the frame.
1 more element
Dependencies are inferred from the claim text.