Blocker door assembly having a thermoplastic blocker door for use in a turbine engine

1. A blocker door assembly for use in a gas turbine engine, said blocker door assembly comprising:

a facesheet, wherein said facesheet comprises a plurality of openings to facilitate noise attenuation; and

a body portion coupled to said facesheet, wherein said body portion comprises a backsheet integrally formed with a honeycomb core, said body portion further comprises a plurality of mounting structures integrally formed with said backsheet and said honeycomb core, wherein said backsheet, said honeycomb core, and said mounting structures are co-molded from a thermoplastic material.

2. The blocker door assembly according to claim 1 , wherein said facesheet is formed from the thermoplastic material.

3. The blocker door assembly according to claim 1 , wherein said honeycomb core comprises a plurality of cells comprising a plurality of walls, and wherein said plurality of cells comprises a plurality of sets of cells, wherein each set of cells comprises a wall thickness that is different than a wall thickness of every other set of cells.

4. The blocker door assembly according to claim 1 , wherein said facesheet is coupled to said body portion by at least one of thermal bonding, adhesive bonding, and a plurality of mechanical fasteners.

5. The blocker door assembly according to claim 1 , wherein said body portion comprises a first portion and a second portion, wherein said blocker door assembly further comprises an intermediate sheet coupled between said first and said second portions.

6. The blocker door assembly according to claim 5 , wherein said intermediate sheet is formed from the thermoplastic material and facilitates noise attenuation.

7. A body portion of a blocker door assembly for use in a gas turbine engine, said body portion comprising:

a backsheet;

a honeycomb core integrally formed with said backsheet from a thermoplastic material, wherein said honeycomb core comprises a plurality of cells comprising a plurality of walls; and

at least one stiffening rib co-molded with said backsheet and said honeycomb core from the thermoplastic material.

8. The body portion according to claim 7 , wherein said plurality of cells comprises a plurality of sets of cells, wherein each set of cells comprises a wall thickness that is different than a wall thickness of every other set of cells.

9. The body portion according to claim 8 , wherein said plurality of cells comprises a first set of cells each comprising a first set of walls and a second set of cells each comprising a second set of walls, wherein said first set of walls include a first thickness and said second set of walls include a second thickness larger than the first thickness.

10. The body portion claim 9 , wherein said second set of cells are positioned adjacent said stiffening rib.

11. The body portion claim 7 , wherein said at least one stiffening rib extends from said backsheet towards a distal end of said plurality of walls, and wherein said at least one stiffening rib extends a first distance from said backsheet and said plurality of walls extend a second distance from said backsheet that is larger than the first distance.

12. The body portion claim 7 , further comprising a plurality of mounting structures integrally formed with said honeycomb core and said backsheet.

13. A method of manufacturing a blocker door for use in a gas turbine engine, said method comprising:

forming a facesheet from at least one of a thermoplastic material and a composite material, wherein the facesheet includes a plurality of openings to facilitate noise attenuation; and

forming a body portion from the thermoplastic material using molding, wherein forming a body portion includes integrally forming a honeycomb core and a backsheet from the thermoplastic material, wherein forming the body portion includes co-molding the backsheet, the honeycomb core, and a plurality of mounting structures from the thermoplastic material; and

coupling the facesheet to the body portion.

14. The method according to claim 13 , wherein forming a honeycomb core comprises forming a honeycomb core including a plurality of cells having a plurality of walls, wherein the plurality of cells includes a plurality of sets of cells, wherein each set of cells includes a wall thickness that is different than a wall thickness of every other set of cells.

15. The method according to claim 13 , wherein coupling the facesheet to the body portion includes coupling the facesheet to the body portion using at least one of thermal bonding, adhesive bonding, and a plurality of mechanical fasteners.

16. The method according to claim 13 , wherein forming a body portion includes forming a first body portion and forming a second body portion, and wherein the method further comprises:

forming an intermediate sheet from the thermoplastic material; and

coupling the intermediate sheet between the first body portion and the second body portion.

17. A method of manufacturing a body portion of a blocker door assembly for use in a gas turbine engine, said method comprising:

forming a backsheet from a thermoplastic material;

integrally forming a honeycomb core with the backsheet from the thermoplastic material, wherein the honeycomb core includes a plurality of cells including a plurality of walls; and

co-molding at least one stiffening rib with the backsheet and the honeycomb core from the thermoplastic material.

18. The method claim 17 , further comprising co-molding a plurality of mounting structures with the honeycomb core and the backsheet from the thermoplastic material.

19. The method according to claim 17 , wherein forming the plurality of cells in the honeycomb core comprises forming a plurality of sets of cells, wherein each set of cells includes a wall thickness that is different than a wall thickness of every other set of cells.

20. The method according to claim 17 , forming the plurality of cells in the honeycomb core comprises forming a first set of cells each including a first set of walls and forming a second set of cells each including a second set of walls, wherein the first set of walls include a first thickness and the second set of walls include a second thickness larger than the first thickness.

21. The method according to claim 20 , wherein co-molding the at least one stiffening rib comprises co-molding the at least one stiffening rib adjacent the second set of cells are positioned adjacent said stiffening rib.

22. The body portion claim 17 , wherein co-molding the at least one stiffening rib comprises co-molding the at least one stiffening rib such that at least one stiffening rib extends from the backsheet towards a distal end of the plurality of walls, and wherein the at least one stiffening rib extends a first distance from the backsheet, and wherein the plurality of walls extend a second distance from the backsheet that is larger than the first distance.