Beaded panels and systems and methods for forming beaded panels

Abstract

A beaded panel includes a base panel and a beaded panel doubler made of a first fiber-reinforced thermoplastic composite. The beaded panel doubler is joined to the base panel to supplement a stiffness of the base panel.

What is claimed is: 
     
         1 . A system for fabricating a beaded panel comprising a base panel and a beaded panel doubler, wherein the beaded panel doubler is joined to the base panel to supplement a stiffness of the base panel, the system comprising:
 a panel forming apparatus configured to form the beaded panel doubler, wherein the beaded panel doubler comprises beads and a web that interconnects the beads; and   a panel joining apparatus configured to couple at least a portion of the web of the beaded panel doubler to the base panel.   
     
     
         2 . The system of  claim 1 , wherein the panel forming apparatus comprises one of a stamp forming apparatus, a pultrusion apparatus, a continuous compression molding apparatus, and a press forming apparatus. 
     
     
         3 . The system of  claim 1 , wherein the panel forming apparatus comprises a stamp forming apparatus. 
     
     
         4 . The system of  claim 3 , wherein the stamp forming apparatus comprises:
 a first die comprising a first die surface; and   a second die comprising a second die surface, the second die further comprising die segments, each one of the die segments comprising a die-surface segment that forms a portion of the second die surface.   
     
     
         5 . The system of  claim 4  wherein the first die surface and the second die surface are complementary. 
     
     
         6 . The system of  claim 5  wherein the die segments are actuated according to a predetermined sequence to sequentially form beads and portions of a web that interconnects the beads in a blank. 
     
     
         7 . The system of  claim 6 , wherein the die segments are arranged in a linear series such that the die-surface segment of each one of the die segments forms a portion of second die surface when the die segments are actuated. 
     
     
         8 . The system of  claim 7 , wherein the die segments comprise:
 a first die segment;   a second die segment that is situated at a first side of the first die; and   a third die segment that is situated at a second side of the first die, opposite the second die segment.   
     
     
         9 . The system of  claim 8  wherein the predetermined sequence for actuation of the die segments comprises:
 actuation of the first die segment; 
 actuation of the second die segment; and 
 actuation of the third die segment. 
 
     
     
         10 . The system of  claim 1 , wherein the panel joining apparatus comprises a welding apparatus configured to join at least the portion of the web of the beaded panel doubler and the base panel together by thermoplastic welding. 
     
     
         11 . The system of  claim 10 , wherein the welding apparatus comprises:
 a jig configured to clamp together a base panel and a beaded panel doubler; and   a welding head configured to thermally weld the base panel and the beaded panel doubler together.   
     
     
         12 . The system of  claim 11 , wherein the beaded panel doubler is made of a first fiber-reinforced thermoplastic composite and the base panel is made of a second fiber-reinforced thermoplastic composite. 
     
     
         13 . The system of  claim 12 , wherein the jig comprises openings that provide access to a portion of at least one of the base panel and the beaded panel doubler. 
     
     
         14 . The system of  claim 13 , wherein the welding head is configured to thermally weld the base panel and a portion of the beaded panel doubler together along the openings. 
     
     
         15 . The system of  claim 14 , wherein the welding head comprises one of an induction welder, an ultrasonic welder, a resistance welder, and a hot plate welder. 
     
     
         16 . The system of  claim 15 , further comprising a compactor configured to be selectively situated to compress a portion of the base panel and a portion of the beaded panel doubler against the jig during thermal welding. 
     
     
         17 . The system of  claim 15 , wherein the welding head is further configured to thermally weld a structural member to the beaded panel. 
     
     
         18 . The system of  claim 17 , wherein the structural member is made of a third fiber-reinforced thermoplastic composite. 
     
     
         19 . The system of  claim 1  wherein the beaded panel doubler comprises beads and a web that interconnects the beads, and wherein at least one of the beads of the beaded panel doubler comprises a closed end. 
     
     
         20 . A method for forming a beaded panel, the method comprising steps of:
 forming a beaded panel doubler, wherein the beaded panel doubler is made of a first fiber-reinforced thermoplastic composite and comprises beads and a web that interconnects the beads; and   joining at least a portion of the web of the beaded panel doubler and a base panel together to supplement a stiffness of the base panel.