Composite structures and methods of forming composite structures
Composite structures and methods of forming composite structures are provided. The composite structures can include one or more composite structure components. Each composite structure component is formed from a composite panel that includes one or more sheets of material. The sheets of material include a thermoplastic material and a plurality of reinforcing fibers. A composite panel can be formed in three dimensions to form a composite structure component. Multiple composite structure components can be fused to one another to form a composite structure. In addition, each composite structure component and the composite structure formed therefrom can include an aperture. An interior volume can be formed between adjacent composite structure components. Methods for forming a composite structure can include a step of simultaneously molding and fusing composite structure components.
1 . A structure, comprising:
a first composite structure component, including:
a plurality of sheets of thermoplastic material, wherein at least some of the sheets include a plurality of fibers;
an outside edge; and
an inside edge formed exclusively of the thermoplastic material alone, being continuous and formed in a closed loop; and
a second composite structure component, including:
a plurality of sheets of the thermoplastic material, wherein at least some of the sheets include a plurality of fibers;
an outside edge; and
an inside edge formed exclusively of the thermoplastic material alone, being continuous and formed in a closed loop,
wherein the inside edge of the first composite structure component is edge-to-edge welded to the inside edge of the second composite structure component, and the outside edge of the first composite structure component is edge-to-edge welded to the outside edge of the second composite structure component, forming welded joints; and
wherein an interior volume expands between adjacent interior surfaces of the first and second composite structure components and between the inside edges and the outside edges that are edge-to-edge welded.
2 . The structure of claim 1 , further comprising a first auxiliary aperture formed in the first composite structure component.
3 . The structure of claim 2 , further comprising a second auxiliary aperture formed in the second composite structure component.
4 . The structure of claim 3 , wherein the first auxiliary aperture is adjacent to the second auxiliary aperture.