Thermoplastic aerostructure with localized ply isolation and method for forming aerostructure

Abstract

A composite wingbox structure formed of reinforced thermoplastic. The composite includes carbon fiber reinforcement and a plurality of insulation elements to localize the heat formed during the process of manufacturing the structure. The process of manufacturing the wingbox includes the steps of interleaving a series of insulations elements within a plurality of laminae and consolidating the insulation elements and laminae to form a laminate. The laminate is then aligned with a support structure such that the insulation elements overlie the supports structure. The laminate is then fused to the support structure using a non-contact heating process, such as inductive welding.

1 - 22 . (canceled) 
     
     
         23 . An aerostructure having an enclosure disposed therein, comprising a skin formed from a composite material, the skin having a shape and configuration to provide the enclosure therein, and the composite material including conjoined layers of at least one first material layer and at least one a second material layer, the first material layer including a unidirectional carbon fiber reinforced thermoplastic material and the second material layer including an electrically insulating material. 
     
     
         24 . The aerostructure of  claim 23 , wherein the at least one first material layer includes a plurality of first material layers and the at least one second material layer includes a plurality of second material layers, with selected ones of the first material layers and second material layers disposed in a stack of alternating layers. 
     
     
         25 . The aerostructure of  claim 24 , wherein plurality of first material layers includes a first layer having the unidirectional carbon fibers oriented in a first direction and second layer having the unidirectional carbon fibers oriented in a second direction different from the first direction. 
     
     
         26 . The aerostructure of  claim 25 , wherein first and second directions are oriented 0 degrees relative to one another. 
     
     
         27 . The aerostructure of  claim 25 , wherein first and second directions are oriented 45 degrees relative to one another. 
     
     
         28 . The aerostructure of  claim 25 , wherein first and second directions are oriented 90 degrees relative to one another. 
     
     
         29 . The aerostructure of  claim 24 , wherein the stack of alternating layers is configured such that an electromagnetic field applied proximate a first side of the stack is able to melt a selected first material layer of unidirectional carbon fiber reinforced thermoplastic material located at a second side of the stack opposing the first side, without melting a selected first layer of unidirectional carbon fiber reinforced thermoplastic material at the first side of the stack. 
     
     
         30 . The aerostructure of  claim 24 , wherein the stack of alternating layers is configured such that cooperation between the electrically insulating material and an electromagnetic field applied proximate a first side of the stack is able to melt a selected first material layer of unidirectional carbon fiber reinforced thermoplastic material located at a second side of the stack opposing the first side, without melting a selected first layer of unidirectional carbon fiber reinforced thermoplastic material at the first side of the stack. 
     
     
         31 . The aerostructure of  claim 23 , wherein the unidirectional carbon fiber lie within a plane containing the first material layer. 
     
     
         32 . The aerostructure of  claim 23 , comprising a support structure disposed in the enclosure. 
     
     
         33 . The aerostructure of  claim 32 , wherein the skin is wrapped around the support structure to form an enclosed support assembly. 
     
     
         34 . The aerostructure of  claim 32 , wherein the support structure comprises spars, ribs, or combinations thereof. 
     
     
         35 . The aerostructure of  claim 23 , wherein the electrically insulating material includes glass. 
     
     
         36 . The aerostructure of  claim 23 , wherein the skin includes a separate upper skin piece and a separate lower skin piece each piece joined to one another to provide the skin having an enclosure disposed therein. 
     
     
         37 . The aerostructure of  claim 23 , wherein the unidirectional carbon fiber reinforced thermoplastic material is a prepreg material. 
     
     
         38 . The aerostructure of  claim 23 , wherein the carbon fiber reinforced thermoplastic material comprises a polymer in the polyaryletherketone (PAEK) family. 
     
     
         39 . The aerostructure of  claim 23 , wherein conjoined layers of at least one first material layer and at least one a second material layer are provided in the form of a consolidated laminate. 
     
     
         40 . The aerostructure of  claim 23 , wherein the electrically insulating material includes a material that can be heat fused with the unidirectional carbon fiber reinforced thermoplastic material. 
     
     
         41 . The aerostructure of  claim 23 , wherein the second material layer is configured to form a pattern that corresponds to the portions of the skin intended to be heated. 
     
     
         42 . The aerostructure of  claim 41 , wherein the pattern has a plurality of openings. 
     
     
         43 . The aerostructure of  claim 23 , wherein the second material layer is a glass tape.