US 11,993,388 B2
Corrugated stiffening devices utilizing peaks and valleys and methods of manufacture
Jennifer Davis, La Jolla, CA (US); and Nathaniel M. Gray, Stratham, NH (US)
Assigned to ROHR, INC., Chula Vista, CA (US)
Filed by ROHR, INC., Chula Vista, CA (US)
Filed on Sep. 2, 2021, as Appl. No. 17/465,027.
Prior Publication US 2023/0066332 A1, Mar. 2, 2023
Int. Cl. B29C 70/34 (2006.01); B29C 65/00 (2006.01); B29C 65/02 (2006.01); B29C 70/44 (2006.01); B32B 37/00 (2006.01); B64D 29/08 (2006.01); B29K 101/12 (2006.01); B29L 31/00 (2006.01)
CPC B64D 29/08 (2013.01) [B29C 65/02 (2013.01); B29C 66/0342 (2013.01); B29C 70/345 (2013.01); B32B 37/00 (2013.01); B29K 2101/12 (2013.01); B29L 2031/7504 (2013.01); B32B 2250/02 (2013.01); B32B 2250/242 (2013.01)] 20 Claims
OG exemplary drawing
 
1. 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.