Thermoplastic acoustic blocker door

Abstract

A thrust reverser blocker door includes a body portion and a mounting structure coupled to the body portion. The body portion includes a facesheet, a backsheet, and a honeycomb core. The facesheet and/or the backsheet comprises a first thermoplastic material and the mounting structure comprises a second thermoplastic material. A method for manufacturing a thrust reverser blocker door may comprise thermoforming a sandwich panel comprising a facesheet, a backsheet, and a honeycomb core. The method may further comprising overmolding a mounting structure onto the backsheet. The first thermoplastic material may comprise a continuous fiber reinforced thermoplastic composite material. The second thermoplastic material may comprise a discontinuous fiber reinforced thermoplastic composite material.

What is claimed is: 
     
         1 . A thrust reverser blocker door, comprising:
 a body portion comprising a facesheet, a backsheet, and a honeycomb core; and   a mounting structure coupled to the backsheet;   wherein at least one of the facesheet and the backsheet comprises a first thermoplastic material and the mounting structure comprises a second thermoplastic material.   
     
     
         2 . The thrust reverser blocker door of  claim 1 , wherein the first thermoplastic material comprises a continuous fiber reinforced thermoplastic composite material. 
     
     
         3 . The thrust reverser blocker door of  claim 2 , wherein the second thermoplastic material comprises a discontinuous fiber reinforced thermoplastic composite material. 
     
     
         4 . The thrust reverser blocker door of  claim 3 , wherein the mounting structure is interdiffused with the backsheet via an overmolding process. 
     
     
         5 . The thrust reverser blocker door of  claim 4 , further comprising a plurality of openings disposed in the facesheet. 
     
     
         6 . The thrust reverser blocker door of  claim 5 , wherein the plurality of openings are in fluid communication with the honeycomb core. 
     
     
         7 . The thrust reverser blocker door of  claim 1 , further comprising a close-out coupled around a perimeter of the thrust reverser blocker door. 
     
     
         8 . The thrust reverser blocker door of  claim 1 , wherein the facesheet, the backsheet, and the honeycomb are formed as a single-piece component.