US 12,280,553 B2
Fiber-reinforced thermoplastic composite structural members, aircraft including the same, and related methods
Adriana W. Blom-Schieber, Snohomish, WA (US)
Assigned to The Boeing Company, Arlington, VA (US)
Filed by The Boeing Company, Arlington, VA (US)
Filed on Apr. 5, 2023, as Appl. No. 18/295,979.
Prior Publication US 2024/0336016 A1, Oct. 10, 2024
Int. Cl. B29C 65/02 (2006.01); B29C 65/00 (2006.01); B29L 31/30 (2006.01); B64C 1/00 (2006.01)
CPC B29C 66/721 (2013.01) [B29C 65/02 (2013.01); B29C 66/52441 (2013.01); B29C 66/914 (2013.01); B29L 2031/3076 (2013.01); B64C 2001/0072 (2013.01)] 20 Claims
 
1. A method of forming a fiber-reinforced thermoplastic composite structural member from a first thermoplastic sub-structure and a second thermoplastic sub-structure, wherein the first thermoplastic sub-structure includes a first web, a first flange that extends away from the first web, and a first transition region between the first flange and the first web, wherein the second thermoplastic sub-structure includes a second web, a second flange that extends away from the second web, and a second transition region between the second flange and the second web, the method comprising:
positioning the first thermoplastic sub-structure and the second thermoplastic sub-structure relative to one another such that the first flange extends away from the second flange and also such that the first web faces the second web;
compressing the first web and the second web together; and
welding the first web and the second web to one another to at least partially define the fiber-reinforced thermoplastic composite structural member, wherein, during the welding the first web and the second web to one another, the method further includes maintaining the first flange and the first transition region below a melt temperature of the first thermoplastic sub-structure and maintaining the second flange and the second transition region below a melt temperature of the second thermoplastic sub-structure.