US 12,351,305 B2
Thermoplastic composite structure and methods for forming
Shyan Bob Shen, San Diego, CA (US); Michael van Tooren, San Diego, CA (US); Daniel O. Ursenbach, El Cajon, CA (US); and Jeffrey D. Woods, Beaumont, CA (US)
Assigned to Rohr, Inc., Chula Vista, CA (US)
Filed by Rohr, Inc., Chula Vista, CA (US)
Filed on Jul. 28, 2023, as Appl. No. 18/227,685.
Prior Publication US 2025/0033756 A1, Jan. 30, 2025
Int. Cl. B64C 3/26 (2006.01); B29C 65/08 (2006.01); B29L 31/30 (2006.01); B64C 3/18 (2006.01); B64F 5/10 (2017.01)
CPC B64C 3/26 (2013.01) [B29C 65/081 (2013.01); B64C 3/185 (2013.01); B64F 5/10 (2017.01); B29L 2031/3085 (2013.01)] 14 Claims
OG exemplary drawing
 
1. 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;
wherein the first flange of the thermoplastic rib is abutted against an exterior surface of the thermoplastic spar.