US-12617162-B2 - Forming thermoplastic structure stamping blank using automated fiber placement device

Abstract

A method is provided for forming a thermoplastic structure. During this method, a substrate is provided. The substrate includes a substrate thermoplastic and a plurality of substrate fibers disposed within the substrate thermoplastic. The substrate fibers are arranged in a substrate pattern. A first layer is deposited on the substrate using an automated fiber placement device. The first layer includes a first layer thermoplastic and a plurality of first layer fibers disposed within the first layer thermoplastic. The first layer fibers are arranged in a first layer pattern that is different than the substrate pattern. A blank is stamped into the thermoplastic structure. The blank includes the substrate and the first layer where the first layer thermoplastic is consolidated with the substrate thermoplastic.

Inventors

• JAVIER LACALLE

Assignees

• ROHR, INC.

Dates

Publication Date

20260505

Application Date

20221114

Claims (15)

1. 1 . A method for forming a thermoplastic structure, comprising: providing a substrate, the substrate including a substrate thermoplastic and a plurality of substrate fibers disposed within the substrate thermoplastic, the plurality of substrate fibers arranged in a substrate pattern, and a first of the plurality of substrate fibers following a straight trajectory within the substrate thermoplastic; depositing a first layer on a surface of the substrate using an automated fiber placement device, the first layer including a first layer thermoplastic and a plurality of first layer fibers disposed within the first layer thermoplastic, the plurality of first layer fibers arranged in a first layer pattern that is different than the substrate pattern, and a first of the plurality of first layer fibers following a non-straight trajectory within the first layer thermoplastic when viewed in a reference plane parallel to the surface of the substrate; providing a second substrate, the second substrate including a second substrate thermoplastic and a plurality of second substrate fibers disposed within the second substrate thermoplastic, and the plurality of second substrate fibers arranged in a second substrate pattern; depositing a second layer on the second substrate using the automated fiber placement device, the second layer including a second layer thermoplastic and a plurality of second layer fibers disposed within the second layer thermoplastic, and the plurality of second layer fibers arranged in a second layer pattern that is different than the second substrate pattern; stacking the second substrate with the second layer onto the substrate with the first layer to provide a multi-layer stack; consolidating the multi-layer stack together to provide a blank; and stamping the blank to provide the thermoplastic structure.
2. 2 . The method of claim 1 , wherein the substrate comprises a two-dimensional laminate.
3. 3 . The method of claim 1 , wherein the substrate pattern is a unidirectional pattern of the plurality of substrate fibers.
4. 4 . The method of claim 1 , wherein the substrate pattern comprises a weave of the plurality of substrate fibers.
5. 5 . The method of claim 1 , wherein the substrate is configured as a pre-consolidated laminate.
6. 6 . The method of claim 1 , wherein the substrate comprises a sheet of prepreg material; and the first layer is deposited on the sheet of prepreg material.
7. 7 . The method of claim 1 , wherein the first layer thermoplastic is consolidated with the substrate thermoplastic during the depositing of the first layer using the automated fiber placement device.
8. 8 . The method of claim 1 , further comprising consolidating the first layer thermoplastic with the substrate thermoplastic following the depositing of the first layer.
9. 9 . The method of claim 1 , wherein the first layer is deposited on a select portion of the substrate.
10. 10 . The method of claim 1 , wherein the substrate has an outer peripheral substrate geometry; and the first layer has an outer peripheral first layer geometry that is different than the outer peripheral substrate geometry.
11. 11 . The method of claim 1 , further comprising removing at least a portion of the substrate not covered by the first layer.
12. 12 . A method for forming a thermoplastic structure, comprising: providing a first substrate, the first substrate including a first substrate thermoplastic and a plurality of first substrate fibers disposed within the first substrate thermoplastic; depositing a first layer on the first substrate using an automated fiber placement device to provide a first laminate member, the first layer including a first layer thermoplastic and a plurality of first layer fibers disposed within the first layer thermoplastic; providing a second substrate, the second substrate including a second substrate thermoplastic and a plurality of second substrate fibers disposed within the second substrate thermoplastic; depositing a second layer on the second substrate using the automated fiber placement device to provide a second laminate member, the second layer including a second layer thermoplastic and a plurality of second layer fibers disposed within the second layer thermoplastic; subsequently stacking the first laminate member and the second laminate member to provide a multi-layer stack; consolidating the multi-layer stack together to provide a blank; and stamping the blank to provide the thermoplastic structure.
13. 13 . The method of claim 12 , wherein the first substrate comprises a two-dimensional laminate.
14. 14 . The method of claim 12 , wherein the plurality of first substrate fibers are arranged in a first substrate pattern, and the plurality of first layer fibers are arranged in a first layer pattern that is different than the first substrate pattern.
15. 15 . The method of claim 12 , wherein the first substrate is configured as a pre-consolidated laminate.

Description

BACKGROUND 1. Technical Field This disclosure relates generally to forming a thermoplastic structure and, more particularly, to forming the thermoplastic structure by stamping a stamping blank. 2. Background Information A structure may be formed by stamping a fiber-reinforced polymer stamping blank. The stamping blank may be configured as a consolidated laminate of multiple layers. Each laminate layer may include a standard woven mesh, unidirectional or other types of fibers embedded within a polymer matrix. While the standard woven mesh of fibers and generic, constant thickness laminates may be readily available and inexpensive, it may be difficult provide the stamped structure with optimal fiber placement and orientation. There is a need in the art therefore for an improved method for forming a fiber-reinforced polymer structure with tailored fiber placement and/or orientation. SUMMARY OF THE DISCLOSURE According to an aspect of the present disclosure, a method is provided for forming a thermoplastic structure. During this method, a substrate is provided. The substrate includes a substrate thermoplastic and a plurality of substrate fibers disposed within the substrate thermoplastic. The substrate fibers are arranged in a substrate pattern. A first layer is deposited on the substrate using an automated fiber placement device. The first layer includes a first layer thermoplastic and a plurality of first layer fibers disposed within the first layer thermoplastic. The first layer fibers are arranged in a first layer pattern that is different than the substrate pattern. A blank is stamped into the thermoplastic structure. The blank includes the substrate and the first layer where the first layer thermoplastic is consolidated with the substrate thermoplastic. According to another aspect of the present disclosure, another method is provided for forming a thermoplastic structure. During this method, a substrate is provided. The substrate includes a substrate thermoplastic and a plurality of substrate fibers disposed within the substrate thermoplastic. A first layer is deposited on the substrate using an automated fiber placement device. The first layer includes a first layer thermoplastic and a plurality of first layer fibers disposed within the first layer thermoplastic. The substrate is formed independent of the automated fiber placement device. A blank is stamped into the thermoplastic structure. The blank includes the substrate and the first layer where the first layer thermoplastic is consolidated with the substrate thermoplastic. According to still another aspect of the present disclosure, another method is provided for forming a thermoplastic structure. During this method, a first substrate is provided. The first substrate includes a first substrate thermoplastic and a plurality of first substrate fibers disposed within the first substrate thermoplastic. A first layer is deposited on the first substrate using an automated fiber placement device to provide a first laminate member. The first layer includes a first layer thermoplastic and a plurality of first layer fibers disposed within the first layer thermoplastic. A second substrate is provided. The second substrate includes a second substrate thermoplastic and a plurality of second substrate fibers disposed within the second substrate thermoplastic. A second layer is deposited on the second substrate using the automated fiber placement device to provide a second laminate member. The second layer includes a second layer thermoplastic and a plurality of second layer fibers disposed within the second layer thermoplastic. A multi-layer stack includes the first laminate member and the second laminate member on the first laminate member. The multi-layer stack is consolidated together to provide a blank. The blank is stamped into the thermoplastic structure. The substrate fibers may be arranged in a substrate pattern. The first layer fibers may be arranged in a first layer pattern that is different than the substrate pattern. A first of the substrate fibers may follow a straight trajectory within the substrate thermoplastic. A first of the first layer fibers may follow a non-straight trajectory within the first layer thermoplastic. The substrate fibers may be uniformly spaced within the substrate thermoplastic. At least some of the first layer fibers may be non-uniformly spaced within the first layer thermoplastic. The substrate may be configured as or otherwise include a two-dimensional laminate. The substrate pattern may be configured as or otherwise include a unidirectional pattern of the substrate fibers. The substrate pattern may be configured as or otherwise include a weave of the substrate fibers. The substrate may be configured as a pre-consolidated laminate. The substrate may be configured as or otherwise include a sheet of prepreg material. The first layer may be deposited on the sheet of prepreg material. The first layer thermoplastic may be consolid