US 11,691,357 B2
Thermoplastic composite panel systems and methods
Samantha Landis, Tustin, CA (US); Guinevere Berg, Encinitas, CA (US); Andrew Cai, San Diego, CA (US); and Johann Steven Schrell, San Diego, CA (US)
Assigned to ROHR, INC., Chula Vista, CA (US)
Filed by ROHR, INC., Chula Vista, CA (US)
Filed on Feb. 3, 2020, as Appl. No. 16/780,569.
Prior Publication US 2021/0237373 A1, Aug. 5, 2021
Int. Cl. B29C 43/00 (2006.01); B29C 70/00 (2006.01); B29C 70/42 (2006.01); B29C 43/18 (2006.01); B29C 65/00 (2006.01); B29K 101/12 (2006.01); B29K 105/06 (2006.01); B29L 31/30 (2006.01)
CPC B29C 70/42 (2013.01) [B29C 43/003 (2013.01); B29C 43/18 (2013.01); B29C 66/721 (2013.01); B29K 2101/12 (2013.01); B29K 2105/06 (2013.01); B29L 2031/3076 (2013.01)] 19 Claims
OG exemplary drawing
 
1. A method for forming a fiber-reinforced thermoplastic control surface, comprising:
stacking plies of thermoplastic composite sheets to a desired thickness to form a first skin;
transferring the first skin to an overmolding tool;
heating the overmolding tool;
compressing, via the overmolding tool, the first skin;
injecting a discontinuous fiber-reinforced thermoplastic material between the overmolding tool and the first skin to form a stiffener structure;
simultaneously consolidating the first skin and the stiffener structure, wherein the first skin is formed into a desired shape in response to being compressed by the overmolding tool;
attaching the first skin to a second skin; and
attaching a sidewall between and to the first skin and the second skin, wherein the sidewall at least partially encloses the stiffener structure between the first skin and the second skin.