Thermoplastic truss structure for use in wing and rotor blade structures and methods for manufacture

Abstract

The present disclosure generally relates to thermoplastic truss structures and methods of forming the same. The truss structures are formed using thermoplastic materials, such as fiber reinforced thermoplastic resins, and facilitate directional load support based on the shape of the truss structure. In one example, multiple two-dimensional patterns of fiber reinforced thermoplastic resin are disposed on one another in a saw tooth pattern, sinusoidal pattern, or other repeating pattern, and adhered to one another in selective locations. The two dimensional patterns may then be expanded in a third dimension to form a three-dimensional, cross-linked truss structure. The three-dimensional, cross-linked truss structure may then be heated or otherwise treated to maintain the three-dimensional shape.

What is claimed is: 
     
         1 . A method of forming a support structure, comprising:
 positioning a first wire segment of thermoplastic material, the first wire segment having a first saw tooth pattern;   positioning a second wire segment of thermoplastic material over the first wire segment, the second segment wire segment having a second saw tooth pattern offset from the first saw tooth pattern;   adhering the second wire segment to the first wire segment;   positioning a third wire segment of thermoplastic material over the second wire segment, the third wire segment having the first saw tooth pattern, the third wire segment aligned with the first wire segment and offset from the second wire segment; and   adhering the third wire segment to the first wire segment.   
     
     
         2 . The method of  claim 1 , further comprising expanding the first wire segment, the second wire segment, and the third wire segment. 
     
     
         3 . The method of  claim 1 , further comprising disposing a fourth wire segment over the third wire segment, the fourth wire segment having the second saw tooth pattern, the fourth wire segment aligned with the second wire segment. 
     
     
         4 . The method of  claim 3 , further comprising adhering the fourth wire segment to the second wire segment and the third wire segment. 
     
     
         5 . The method of  claim 4 , further comprising disposing fifth wire segment over the fourth wire segment, the fifth wire segment having the first saw tooth pattern and aligned with the first wire segment and the third wire segment. 
     
     
         6 . The method of  claim 5 , further comprising adhering the firth wire segment to the third wire segment. 
     
     
         7 . The method of  claim 1 , wherein adhering the second wire segment to the first wire segment comprises fusion bonding the second wire segment to the first wire segment. 
     
     
         8 . The method of  claim 7 , further comprising heat treating the first wire segment, the second wire segment, and the third wire segment after expanding the first wire segment, the second wire segment, and the third wire segment. 
     
     
         9 . The method of  claim 1 , further comprising adhering a thermoplastic skin to the first wire segment, the second wire segment, and the third wire segment. 
     
     
         10 . The method of  claim 1 , further comprising maintaining the first wire segment, the second wire segment, and the third wire segment in an expanded configuration using a soluble tooling medium. 
     
     
         11 . A method of forming a support structure, comprising:
 positioning a first wire segment of thermoplastic material, the first wire segment having a first saw tooth pattern;   positioning a second wire segment of thermoplastic material over the first wire segment, the second segment wire segment having a second saw tooth pattern offset from the first saw tooth pattern;   adhering the second wire segment to the first wire segment by fusion bonding;   positioning a third wire segment of thermoplastic material over the second wire segment, the third wire segment having the first saw tooth pattern, the third wire segment aligned with the first wire segment and offset from the second wire segment; and   adhering the third wire segment to the first wire segment by fusion bonding.   
     
     
         12 . The method of  claim 11 , wherein the first wire segment, the second wire segment, and third wire segment each include fibers impregnated therein. 
     
     
         13 . The method of  claim 11 , wherein the first wire segment, the second wire segment, and third wire segment each comprise carbon fiber. 
     
     
         14 . The method of  claim 11 , wherein the first wire segment, the second wire segment, and third wire segment each comprise polyetherketoneketone. 
     
     
         15 . The method of  claim 11 , wherein the first wire segment, the second wire segment, and third wire segment each comprise polyetheretherketone. 
     
     
         16 . The method of  claim 11 , wherein the first wire segment, the second wire segment, and third wire segment are hollow. 
     
     
         17 . The method of  claim 11 , further comprising fusion bonding a skin to one or more of the first wire segment, the second wire segment, and third wire segment. 
     
     
         18 . A method of forming a support structure, comprising:
 positioning a first wire segment of thermoplastic material, the first wire segment having a first saw tooth pattern;   positioning a second wire segment of thermoplastic material over the first wire segment, the second segment wire segment having a second saw tooth pattern offset from the first saw tooth pattern;   adhering the first wire segment to the second wire segment at intersections thereof by diffusion bonding;   positioning a third wire segment of thermoplastic material over the second wire segment, the third wire segment having the first saw tooth pattern, the third wire segment aligned with the first wire segment and offset from the second wire segment; and   adhering upper axes of the third wire segment to upper apexes of the first wire segment.   
     
     
         19 . The method of  claim 18 , further comprising disposing a fourth wire segment over the third wire segment, the fourth wire segment having the second saw tooth pattern, the fourth wire segment aligned with the second wire segment. 
     
     
         20 . The method of  claim 19 , further comprising adhering lowering apexes of the fourth wire segment to the lower apexes of the second wire segment.