Methods of punch forming fiber reinforced thermoplastic composite components and related systems

Abstract

The invention provides a method of punch forming a fiber reinforced thermoplastic composite component and a related system. Punch forming the composite assembly includes applying a low melt film on an interface surface of at least one spar, loading the spar onto at least one tooling section such that the interface surface is exposed, and heating the tooling section to a first temperature that is higher than a crystallization temperature of the low melt film and lower than a melting temperature of the spar resin. A second low melt film may be applied on the fiber reinforced thermoplastic skin blank and the skin blank is heated to a second temperature that is higher than the melt temperature of the skin blank resin. The skin blank is then covered around the tooling section such that at least some of the second low melt film contacts the low melt film on the interface surface of the spar. And then the punching machine is closed, so that the skin blank and the spar are jointly consolidated, and the composite assembly is formed through punching.

Description

Technical Field

[0001] The present disclosure relates generally to stamping and forming fiber reinforced thermoplastic composite components and, more particularly, to such methods of co-consolidating skins and spars together. Background Art

[0002] The traditional method of forming thermoplastic composite closed-profile torsion boxes, such as aircraft wing boxes, involves forming the skin and spar separately, then inserting the spar and fastening or welding it to the skin in a second step. Potential disadvantages of this technique include the need for multiple steps to fasten the spar to the skin, and the difficulty of inserting the spar in an assembly with closed leading and trailing edges without causing tolerance issues in the final part. Summary of the invention

[0003] The disclosed method can improve upon the prior art, for example by reducing the number of process steps used to form a composite component such as a torsion box having closed leading and trailing edges. Generally, such methods involve forming a thermoplastic composite skin and co-consolidating the skin with a preformed spar in a single stamping and forming action.

[0004] In a specific example, the method of stamping a fiber reinforced thermoplastic composite component according to the present disclosure may include applying a first low-melting film on at least one interface surface of at least one spar, wherein each spar of at least one spar is formed by a fiber reinforced thermoplastic composite material. At least one spar can be loaded onto at least one tooling segment so that at least one interface surface is exposed and faces a direction away from at least one tooling segment. At least one tooling segment can be heated to a first temperature, wherein the first temperature is higher than the crystallization temperature of the first low-melting film and lower than the melting temperature of the thermoplastic spar resin of at least one spar. A second low-melting film (which may be the same film material as the first low-melting film) may be applied to, coated with or disposed on a first side of a fiber reinforced thermoplastic skin blank. As used herein, when a thermoplastic composite skin laminate is in a flat or substantially unformed state, and becomes flexible due to heating and / or deconsolidation, it is referred to as a "skin blank". Once the skin blank has been stamped and consolidated, it will be referred to as a "skin". The skin stock can be heated to a second temperature that is above the melting temperature of the thermoplastic skin resin of the skin stock. In this manner, the skin stock and any second low-melting film thereon can be heated to a point where the skin stock can be draped or placed around at least one tooling segment so that the first side of the skin stock faces the direction of the outer surface of the at least one tooling segment. When the skin stock is so draped, at least some of any second low-melting film on the skin stock can be brought into contact with the first low-melting film on at least one spar interface surface of the spar.

[0005] For stamping composite components, a punch press can be closed around a skin stock and at least one tooling section, the skin stock is pressed into at least one tooling section, and at least some of any second low-melting film are pressed against the first low-melting film on at least one interface surface of the spar. The skin stock and at least one spar can be co-consolidated in a punch press to form the resulting fiber-reinforced thermoplastic composite component formed by the skin and the spar. Once the co-consolidation is completed, the punch press can be opened to remove the composite component and the tooling section from the punch press. The resulting composite component is also within the scope of the present disclosure. For example, the resulting composite component can be a closed profile torsion box, such as a wing tip, a winglet, a rotor blade of an unmanned aerial vehicle (UAV), a rotor blade of a helicopter tail rotor, a wing, aileron, a flap, a rudder and / or a smaller control surface for a UAV, a helicopter or a commercial aircraft.

[0006] Related systems for performing such methods are also within the scope of the present disclosure. An exemplary system may include a plurality of tooling sections configured to position at least one preformed spar for a stamping process; an infrared heater configured to heat a fiber-reinforced thermoplastic consolidation skin blank to a temperature that is higher than the film melting point of a low-melting film applied to at least one preformed spar; a tensioning element configured to maintain tension on the skin blank when the skin blank is covered around a plurality of tooling sections, so that the skin blank faces the outer surface of the plurality of tooling sections; and a punching machine configured to close around the skin blank and the plurality of tooling sections, so that the punching machine is configured to press the skin blank into the plurality of tooling sections and against the low-melting film on at least one preformed spar, so that the skin blank is consolidated with the at least one preformed spar, thereby forming a fiber-reinforced thermoplastic composite component. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1 is a schematic diagram of a non-exclusive example of a wing spar having a low-melt film applied to an interface surface.

[0008] Figure 2 is a schematic cross-sectional view of a plurality of tooling sections having a plurality of spars coupled thereto.

[0009] Figure 3 is a schematic diagram of a plurality of tooling sections being closed together to clamp or grip respective wing spars between respective adjacent tooling sections.

[0010] Figure 4 is a schematic diagram of a skin blank coated with a low-melt film heated in a heater.

[0011] Figure 5 is a schematic diagram of a heated skin blank positioned relative to a plurality of tooling sections and a spar engaged therewith.

[0012] Figure 6 is a schematic diagram of a heated skin blank, which is covered around a plurality of tooling segments to fit the skin blank to the tooling segments.

[0013] Figure 7 Schematic diagram of the tooling section, spar and skin stock enclosed in a stamping press for stamping.

[0014] Figure 8 yes Figure 7 Schematic diagram of the press which has been enclosed around the tooling sections, spar and skin blanks.

[0015] Fig. 9 yes Figure 7-8 Schematic diagram of the press opening from the tooling section, skin and spar.

[0016] Fig.10 is a schematic flow chart showing a method of stamping a composite component according to the present disclosure.

[0017] Fig.11 is a schematic diagram of an alternative arrangement of a press and tooling sections according to the present disclosure.

[0018] Fig.12 is a schematic diagram of an alternative type of press that may be used to stamp and form composite components in accordance with the present disclosure.

[0019] Fig.13 is a schematic diagram of a system for stamping and forming a composite component according to the present disclosure. DETAILED DESCRIPTION

[0020] Figure 1-9 and Figure 11-13 Illustrative, non-exclusive examples of methods and systems for stamping composite components according to the present disclosure are provided and may generally not be drawn to scale. Figure 1-9 and Figure 11-13 In each of the Figures, elements serving similar or at least substantially similar purposes are labeled with the same numerals, and these elements may not be referred to herein as 1-9 and Figure 11-13 Similarly, not all elements can be found in 1-9 and Figure 11-13 The reference numerals associated with them are not marked in each figure, but for consistency, the reference numerals associated with them will be used herein. Figure 1-9 and Figure 11-13 One or more of the elements, components and / or features discussed in may be included in Figure 1-9 and Figure 11-13In general, elements that may be included in a given (i.e., specific) example are represented by solid lines, while elements that are optional for a given example are represented by dashed lines. However, elements represented by solid lines are not essential for all examples, and elements represented by solid lines may be omitted from a specific example without departing from the scope of the present disclosure.

[0021] Figure 1 A schematic diagram of a side view of a spar 10 is shown, which may be a preformed fiber reinforced thermoplastic composite spar 10. The spar 10 generally includes an elongated portion 12 with two opposing flanges 14 extending from the elongated portion 12 at both ends of the elongated portion 12. A first low-melting film 16 is present on an interface surface 18 of each flange 14, wherein, in this example, the interface surface 18 is the outer surface of each flange 14. The first low-melting film 16 may be coated, applied, adhered and / or laminated on the interface surface 18 of the spar 10. The first low-melting film 16 should be selected to be compatible with the resin used in the fiber reinforcement material used to manufacture the spar 10. The first low-melting film 16 may be applied to the interface surface 18 after preforming the spar 10, before preforming the spar 10, or when the spar 10 is preformed. Examples of suitable low-melting films may be amorphous or semi-crystalline and are disclosed in U.S. Patent Application Publication No. 2022-0266541, the entire disclosure of which is incorporated herein by reference.

[0022] Figure 2 A schematic diagram of a side view of a plurality of tooling segments 20 is shown that can be configured to be used as a mold for manufacturing a co-consolidated thermoplastic composite component. For example, Figure 2 The plurality of tooling segments 20 are illustrated as having a first tooling segment 22, a second tooling segment 24, and a third tooling segment 26, but in other examples, the plurality of tooling segments 20 may include more or fewer tooling segments 20. Additionally or alternatively, each of the one or more tooling segments may be composed of multiple interengaging components. When used for stamping and forming a composite part, the tooling segments 20 may be configured to be assembled together or interengaged. Figure 3 As shown in FIG. 1 , when the tooling segments 20 are assembled together, the outer surface 28 of the combined tooling segments 20 may form an airfoil or teardrop shape, although other shapes are within the scope of the present disclosure.

[0023] Continue to refer Figure 2 and Figure 3, the tooling sections 20 may be configured to receive, support and / or position one or more spars 10 relative to each other. For example, the tooling sections 22, 24, 26 are configured to receive, support and position two spars 10 (e.g., a first spar 10a and a second spar 10b), but in other examples, more or fewer spars 10 may be used. In the illustrated example, the first spar 10a may be positioned on the first tooling section 22, and when the tooling sections 20 are closed together (in Figure 3 In the configuration shown in FIG. 1 , the first spar 10a is sandwiched or clamped between the first tooling section 22 and the third tooling section 26. The second spar 10b can be positioned on the first tooling section 22 opposite to the first spar 10a. When the tooling section 20 is as shown in FIG. Figure 3 When closed as shown, the spar 10 can be clamped or stuck between the first tooling section 22 and the second tooling section 24. When positioned on the tooling section 20 in this way, the spar 10 can be arranged so that when the tooling sections 20 are closed together, the flange 14 and the first low-melting film 16 are still exposed. It can be said that each spar 10 defines a respective channel 50 through the slender portion 12 and the opposing flange 14. When the spar 10 is loaded onto the tooling section 20, the channel 50 of the spar 10 can engage with the tooling section 20. For example, the first channel 50a of the first spar 10a can engage with the first tooling section 22, and the second channel 50b of the second spar 10b can also engage with the first tooling section 22, but is located at the end of the first tooling section 22 opposite to the first spar 10a. In some examples, such as Figure 2-3 As shown, the first spar 10a is oriented relative to the second spar 10b such that the first channel 50a opens toward or faces the second channel 50b of the second spar 10b.

[0024] In some examples, the tooling sections 20 may include features, such as notches 30, for engaging or receiving aspects of the spar 10. For example, when the spars 10a, 10b are positioned on the first tooling section 22, the flange 14 may be configured to engage with the notches 30 on the first tooling section 22. In other examples, the notches 30 may be present on different tooling sections 20 instead of or in addition to the first tooling section 22. In some examples, different features of the tooling sections 20 may engage with the flanges 14 and / or with different aspects of the spar 10. In some examples, the spars 10 may be oriented differently relative to each other and / or relative to one or more tooling sections 20.

[0025] The fiber reinforced skin stock 32 (which may be referred to herein simply as the skin stock 32) may include a second low-melting film 34 on a first side of the skin stock 32. The second low-melting film 34 may be the same type of film as the first low-melting film 16 on the spar 10, or may be a different type of low-melting film that is compatible with the first low-melting film 16 on the spar 10, but in some examples, the skin stock 32 may be provided without any second low-melting film 34. The skin stock 32 and any second low-melting film 34 thereon may be heated, for example, by an infrared (IR) heating system 38, such as Figure 4 Generally, the skin stock 32 is heated to a point where the skin stock 32 becomes flexible enough to be formed, for example, around and / or against the tooling section 20, and the skin stock 32 conforms to the shape formed by the outer surface 28 of the tooling section 20. For example, Figure 5 The schematic diagram shows the positioning of the skin blank 32 relative to the tooling section 20 (the spar 10 is joined to the tooling section 20), and Figure 6 It is schematically shown that the skin blank 32 covers around the tooling section 20 so that the skin blank 32 is in contact with the tooling section 20 .

[0026] To complete the composite assembly 40 of the skin blank 32 and one or more spars 10 (see Fig. 9 ), the punch 42 can be closed around the skin blank 32 and the spar 10, and the skin blank 32 and the spar 10 can be consolidated together in the punch 42. For example, Figure 7 A two-part punch 42 is schematically represented and is indicated as having two halves 42a, 42b, although other configurations and types of punches are within the scope of the present disclosure. Figure 7 The two halves 42a, 42b of the punch press are shown in dotted lines in an open configuration and are then moved towards the skin blank 32 and the tooling section 20 as indicated by arrows 44. Figure 7 4, which has been closed around the skin blank 32, such as overlying the tooling section 20. The punch 42 (e.g., a custom-shaped die of the punch 42) generally defines a recess or cavity 46 between two halves 42a and 42b, which is configured to receive the tooling section 20 and the skin blank 32 therein. The cavity 46 generally has a shape complementary to the tooling section 20, so that the skin blank 32 is pressed on one side by the punch 42 and is subjected to the counterpressure of the tooling section against the first side 36 of the skin blank 32. In this way, the skin blank 32 is pressed into a desired final shape at a sufficiently high temperature to allow the skin blank 32 to be formed, and the skin blank 32 is configured to maintain this desired shape once the skin blank 32 is consolidated and removed from the punch 42 (e.g., once the skin blank 32 transitions to a formed skin through consolidation). Figure 8The skin blank 32, the tooling section 20 and the spar 10 enclosed in the punch press 42 are schematically shown. Fig. 9 The removal of the punch press 42 by moving the halves 42a, 42b away from the composite component 40 formed from the co-consolidated skin blank 32 and the spar 10 (indicated by arrow 48) is schematically shown. Fig. 9 In FIG. 4 , the press halves 42a, 42b are shown in solid lines in an open configuration and in dashed lines as closed around the composite assembly 40. The tooling section 20 can then be removed from the resulting composite assembly 40. Although Figure 7-9 A punch 42 is illustrated in the form of two halves 42a, 42b that move toward and away from the skin blank 32 and the tooling section 20, respectively, to compress or release the skin blank 32 or the skin and tooling section 20, but in other examples within the scope of the present disclosure, the punch 42 may have a different configuration and / or orientation relative to the skin blank 32 and the tooling section 20.

[0027] Fig.10 A flow chart is schematically provided representing an illustrative, non-exclusive example of a method 100 according to the present disclosure. Fig.10 In the embodiment, some steps are represented by dashed boxes, indicating that these steps may be optional, or may correspond to optional versions of the method according to the present disclosure. That is, not all methods according to the present disclosure need to include the steps shown in the solid boxes. Fig.10 The methods and steps shown in are not limiting, and other methods and steps (and orders of steps) are also within the scope of the present disclosure, including methods with more or less than the number of steps shown, as will be understood from the discussion herein. For illustrative purposes, reference may be made to Figure 1-9 The schematic diagram of FIG. 1 describes the steps of method 100 , but is not limited to method 100 .

[0028] A method 100 for stamping a fiber reinforced thermoplastic composite component includes, at 102, applying a first low-melting film (e.g., first low-melting film 16) to at least one interface surface (e.g., interface surface 18) of at least one spar (e.g., spar 10). In this method 100, the spar is formed of a fiber reinforced thermoplastic composite material. After applying the first low-melting film to the spar, the spar is loaded onto one or more tooling segments (e.g., tooling segment 20) at 104 such that the interface surface of the spar faces away from the tooling segment. For example, while other aspects of the spar may be enclosed within the tooling segment (e.g., elongated portion 12, elongated portion 16 may be enclosed within the tooling segment), the spar may be enclosed within the tooling segment. Figure 3), but at this step, the interface surface is not enclosed by the tooling segments, so that the first low-melt film on the interface surface is exposed even when the tooling segments are assembled together. In some examples, the spar can be engaged with the tooling segments so that the interface surface of the spar is substantially flush with the outer surface of the tooling segments. In some examples, loading the spar onto the tooling segments at 104 includes closing the tooling segments together so that two or more tooling segments are engaged with each other. In some examples, when one or more spars are loaded onto the tooling segments and the tooling segments are closed together at 104, portions of them are clamped or stuck between adjacent tooling segments. For example, loading the spars onto the tooling segments at 104 can include loading a first spar onto a first tooling segment, loading a second spar onto the first tooling segment, and / or loading a second spar onto a second tooling segment. In these examples, loading the spar onto the tooling sections at 104 may also include bringing the first tooling section and the second tooling section together to close the first tooling section and the second tooling section together, thereby sandwiching or clamping the second spar between the first tooling section and the second tooling section. Likewise, loading the spar onto the tooling sections at 104 may include bringing the third tooling section together with the first tooling section to sandwich or clamp the first spar between the first tooling section and the third tooling section.

[0029] The method 100 may also include heating the tooling section, the spar, the interface surface of the spar, and / or the ambient temperature of the location where the tooling section is located at 106, so that the first low-melting film on the spar rises to a first temperature, which is higher than the crystallization temperature of the first low-melting film and lower than the melting temperature of the thermoplastic spar resin of the spar. In some examples, heating at 106 causes the tooling section and / or the first low-melting film to be heated to a melting temperature close to the first low-melting film. By limiting the temperature reached by heating the tooling section and the spar at 106, the method 100 can be configured in some examples to heat the first low-melting film to a temperature sufficient to consolidate it together without deconsolidating the spar. This may increase the defect resistance of the resulting composite assembly. The heating at 106 can be a local heating step, which is configured to heat only the interface surface of the first low-melting film and the spar, or the heating at 106 can be an overall heating step, which is configured to heat the entire tooling section assembly and / or the entire spar loaded therein. Additionally, the heating at 106 may also include actively heating one or more tooling segments. In some examples, the method 100 includes cooling (e.g., actively cooling) the tooling segments at one or more time periods during the process. In some examples, the heating at 106 may be performed prior to loading the spar onto the tooling segments at 104.

[0030] A second low-melting film (such as the second low-melting film 34) may be applied to the fiber-reinforced thermoplastic skin stock at 108. In some methods 100, the second low-melting film is the same material as the first low-melting film applied to the spar interface surface, but in other examples, different films may be applied to the spar and the skin stock at 102 and 108, respectively. In some examples, the second low-melting film may be applied to the entire surface or side of the skin stock at 108. In other examples, the second low-melting film may be applied only to a portion of the surface or side of the skin stock. For example, the second low-melting film may be applied to such an area of ​​the skin stock that is configured to contact the first low-melting film applied to the spar. In some examples, the skin stock may be provided without any second low-melting film thereon. Once any second low-melting film is applied to the skin stock at 108 (usually only to one side of the skin stock, such as the first side 36), the skin stock and any second low-melting film are heated at 110. In some examples, heating the skin stock at 110 can be performed using an infrared (IR) heater (such as an IR heating system 38). In general, heating the skin stock at 110 is performed to increase the temperature of the skin stock to a second temperature that is higher than the melting temperature of the thermoplastic skin resin used in the skin stock. Therefore, the heating at 110 can at least partially deconsolidate the skin stock, thereby resulting in giving the skin stock flexibility so that it can be formed as needed. Heating the skin stock at 110 can be performed simultaneously with heating the tooling section at 106, or one heating step can be performed before or after another heating step. In some examples, the skin stock can be suspended and / or tensioned before and / or during heating the skin stock at 110.

[0031] Once the skin stock is sufficiently heated at 110 and the interfacing surface of the spar is sufficiently heated at 106, the skin stock is placed or covered around the tooling segment at 112 (eg, Figure 5-6 Schematically shown in ). In some examples, the skin stock is covered around the tooling section at 112 so that the film temperature of the first low-melting film on the interface surface of the spar is raised to above the film melting point, thereby melting the first low-melting film. When the skin stock is covered around the tooling section at 112, tension is applied to both ends of the skin stock so that the skin stock fits the shape defined by the outer surface of the tooling section. For covering the skin stock at 112, the skin stock and the tooling section are positioned relative to each other so that the first side of the skin stock with the second low-melting film (if any) thereon faces the outer surface of the tooling section. In this way, when the skin stock is covered around the tooling section at 112, at least some of any second low-melting film on the skin stock is contacted with the first low-melting film on the interface surface of the spar engaged with the tooling section.

[0032] Various arrangements for covering the skin stock around the tooling section at 112 are within the scope of the present disclosure. For example, for covering at 112, the skin stock and the tooling section can be positioned relative to each other so that the skin stock is positioned above the tooling section, and then when the skin stock is attached to the tooling section, the skin stock is moved downward toward the tooling section and / or the tooling section is moved upward toward the skin stock. In another arrangement, the skin stock can be positioned relative to the tooling section so that they are side by side, such as Fig.11 Wrapping the skin stock around the tooling section at 112 generally includes maintaining tension on the skin stock during the covering at 112, such as using Figure 5-6 The tensioning element 52 shown in FIG. The tensioning element 52 may be a clamp or a spring, etc., but any suitable mechanism or device may be used for this purpose, as will be understood by those skilled in the art. Figure 11-12 As shown in , the tensioning element 52 is generally connected or engaged with the opposite end or edge of the skin stock and is used to hold the skin stock to maintain tension on the skin stock when it is covered or positioned on or around the tooling segment. In this way, the tensioning element can be used to reduce or prevent wrinkles in the resulting composite assembly. In some examples, the tensioning element can be configured to be rotatable relative to the skin stock.

[0033] Continue to refer Fig.10 , a press (e.g., press 42) may then be closed around the skin stock and the tooling segment at 114, thereby pressing the skin stock into the tooling segment and pressing at least some of any second low-melt film on the skin stock against the first low-melt film on the spar interface surface. Depending on a given setup for performing the disclosed method 100, closing the press at 114 may be performed in a variety of ways. For example, closing the press at 114 may include moving the two halves of the press toward each other to enclose the skin stock and the tooling segment within a cavity defined between the two press halves. For example, Figure 7-9 The punch halves 42 a , 42 b are illustrated moving toward each other and toward either side of the skin blank 32 and tooling segment 20 , thereby enclosing the skin blank 32 and tooling segment 20 within the cavity 46 of the punch 42 . Fig.11 A slightly different arrangement is shown, with the punch halves 42 a , 42 b moving toward the top and bottom sides of the skin blank 32 and tooling section 20 . Fig.12 Another example is schematically illustrated in which the punch press is closed at 114 by moving one half of the punch press toward the other half (eg, moving punch half 42a toward punch half 42b while punch half 42b remains stationary). Figure 11-12 The arrow 54 in the figure indicates the general direction of the process flow. Fig.12In the example of , closing the press at 114 also includes using one half of the press (such as press half 42a) to move the tooling section and the skin stock toward the second half of the press (such as press half 42b). Regardless of the arrangement of the press relative to the tooling section and the skin stock, generally speaking, when the press is closed around the skin stock and the tooling section at 114, any tensioning elements will remain outside the press. Once the resulting composite assembly is co-consolidated and removed from the press, any tensioning elements used to smooth the skin stock in place on the tooling section will generally be removed. In other words, the tensioning elements are generally used to help form the resulting composite assembly, but they themselves do not constitute a part of the resulting composite assembly.

[0034] At 116, the press remains closed around the skin stock and the tooling section until the skin stock and the spar are co-consolidated within the press, thereby forming a fiber-reinforced thermoplastic composite component of the skin and the spar in a single stamping and forming action. In some examples, when the skin stock and the spar are co-consolidated at 116, a certain predetermined pressure or force is applied to the press, and / or the press is actively heated and / or cooled at 128 to assist the consolidation process. In some examples, heating and / or cooling the press at 128 can be performed to maintain a predetermined temperature of the skin stock for a given time period, and / or to change the temperature of the skin stock after a specified time period. The co-consolidation at 116 and / or the heating and / or cooling at 128 can be performed before or after closing the press at 114, and can also be performed until the press is opened at 118 or before the press is opened at 118.

[0035] Once the skin stock and the spar have been co-consolidated, the press may be opened at 118 and the resulting composite component may be removed from the press and / or tooling section at 120. For example, the press may be opened at 118 after the current temperature of the skin and spar is below the crystallization temperature of all of the first thermoplastic resin of the first low-melting film, the second thermoplastic resin of the second low-melting film, the thermoplastic spar resin of the spar, and the thermoplastic skin resin of the skin / skin stock. Additionally or alternatively, the press may be opened at 118 after the resulting fiber-reinforced thermoplastic composite component is below the film melting point of the first low-melting film and any second low-melting film. In some methods 100, the resulting composite component is a closed profile aerodynamic torsion box. For example, the resulting composite component may be a wing tip, a winglet, a rotor blade of an unmanned aerial vehicle (UAV), a rotor blade of a helicopter tail rotor, a wing, an aileron, a flap, a rudder, and / or a smaller control surface for a UAV, a helicopter, or a commercial aircraft.

[0036] Some examples of the method 100 further include trimming the resulting composite component at 122, and / or non-destructively inspecting the composite component at 124. Additionally or alternatively, the method 100 may include forming the spar at 126, such that the spar is preformed. In various examples, the first low-melt film applied at 102 may be applied to the preformed spar at 126. In some examples, the spar may be stamped at 126. In some methods 100, the first low-melt film is applied to the interface surface of the spar during stamping the spar at 126, while in other examples of the method 100, the first low-melt film may be applied to the interface surface of the spar at 104 before or after stamping (or otherwise forming) the spar at 126. In some examples, forming the spar at 126 may include laying up the spar as a flat blank - with the first low-melt film as a surface layer, pre-consolidating the spar in an oven or static press, and then stamping the spar. In another example, forming the spar at 126 may include laying up the spar as a flat blank and then directly stamping the spar. In still another example, forming the spar at 126 may include laying up the material in the final spar shape using an automated fiber placement device and then oven or press consolidating, with a low-melt film applied to the interfacial surface of the spar during consolidation. In other examples, the spar may be formed at 126, as described above, but the low-melt film may be applied after forming.

[0037] The first and / or second low-melting films typically include a thermoplastic resin having a melting temperature lower than the melting temperature of the thermoplastic resin used for the spar (referred to herein as the spar melting temperature of the spar resin). Likewise, the melting temperature of the low-melting film resin is generally lower than the melting temperature of the thermoplastic skin resin used in the skin stock (referred to herein as the skin melting point of the skin resin). In various examples, the film melting point of the first and / or second low-melting film may be at least 20 degrees Fahrenheit lower than the skin melting point, at least 30 degrees Fahrenheit lower than the skin melting point, at least 40 degrees Fahrenheit lower than the skin melting point, at least 50 degrees Fahrenheit lower than the skin melting point, and / or at least 60 degrees Fahrenheit lower than the skin melting point. Additionally or alternatively, the film melting point of the first and / or second low-melting films may be at least 20 degrees Fahrenheit below the spar melting point, at least 30 degrees Fahrenheit below the spar melting point, at least 40 degrees Fahrenheit below the spar melting point, at least 50 degrees Fahrenheit below the spar melting point, and / or at least 60 degrees Fahrenheit below the spar melting point.

[0038] Fig.13An example of a system 60 for press-forming a fiber-reinforced thermoplastic composite component is illustrated. The system 60 generally includes a plurality of tooling sections 20 configured to position at least one preformed spar 10 (for a press-forming process), an infrared heater 38, a tensioning element 52, and a punch 42. As disclosed herein, the heater 38 is configured to heat the fiber-reinforced thermoplastic consolidation skin stock to a temperature above the skin melting point of the skin stock resin. The tensioning element 52 maintains its upper tension when the skin stock 32 is wrapped around the tooling sections 20, and the punch 42 is configured to close around the skin stock 32 and the tooling sections 20, so that the punch 42 is configured to press the skin stock 32 onto the plurality of tooling sections 20 and against the low-melting film on at least one preformed spar 10, so that the skin stock 32 is co-consolidated with one or more spars 10, thereby forming the resulting fiber-reinforced thermoplastic composite component. In some examples, the system 60 includes a cooling system 62 configured for actively cooling the tooling segment 20 and / or the dies of the punch press 42, and / or a heating system 64 configured for actively heating the tooling segment 20 and / or the dies of the punch press 42. In some systems 60, a single temperature control system may be configured to actively heat and cool the tooling segment 20 (and / or the spar 10 engaged therewith).

[0039] Illustrative, non-exclusive examples of inventive subject matter according to the present disclosure are described in the following enumerated paragraphs:

[0040] A1. A method for stamping a fiber-reinforced thermoplastic composite component, the method comprising:

[0041] applying a first low-melting film on at least one interface surface of at least one spar, wherein each spar of the at least one spar is formed of a fiber-reinforced thermoplastic composite material;

[0042] loading the at least one spar onto at least one tooling section such that the at least one interface surface faces away from the at least one tooling section;

[0043] heating the at least one tooling section to bring the first low-melting film to a first temperature, wherein the first temperature is greater than a crystallization temperature of the first low-melting film, and wherein the first temperature is less than a melting temperature of a thermoplastic spar resin of the at least one spar;

[0044] Heating a skin stock to a second temperature, wherein the second temperature is higher than the melting temperature of a thermoplastic skin resin of the skin stock, and wherein the skin stock is a fiber-reinforced thermoplastic skin stock;

[0045] Covering the skin blank around the at least one tooling section so that the first side of the skin blank faces the outer surface of the at least one tooling section;

[0046] closing a punch press around the skin blank and the at least one tooling segment, thereby pressing the skin blank into the at least one tooling segment and pressing the skin blank against the first low-melting film on the at least one interface surface; and

[0047] The skin blank and the at least one spar are co-consolidated within the stamping press to form the fiber reinforced thermoplastic composite component.

[0048] A1.1. The method of paragraph A1, further comprising removing the fiber-reinforced thermoplastic composite component from the at least one tooling section.

[0049] A1.2. The method of paragraph A1 or A1.1, wherein the first low-melting film comprises a first thermoplastic resin having a first film melting temperature that is lower than a spar melting temperature of a thermoplastic spar resin of the at least one spar.

[0050] A1.3. The method of any of paragraphs A1-A1.2, wherein each of the at least one spar includes an elongated portion extending between two opposing flanges.

[0051] A1.4. The method of paragraph A1.3, wherein the at least one interface surface comprises an outer surface of each of two opposing flanges of the at least one spar.

[0052] A1.5. A method according to paragraph A1.4, wherein loading the at least one wing spar onto the at least one tooling segment includes loading the at least one wing spar so that an outer surface of each of two opposing flanges of the at least one wing spar is exposed and faces away from the at least one tooling segment.

[0053] A1.6. The method of any of paragraphs A1-A1.5, further comprising opening the press to remove the at least one tooling segment and the fiber-reinforced thermoplastic composite component.

[0054] A1.7. The method of any of paragraphs A1.6, wherein opening the punch is performed after co-consolidating the skin blank and the at least one spar.

[0055] A1.8. A method according to any of paragraphs A1.6-A1.7, wherein opening the punch is performed after the current temperature of the fiber-reinforced thermoplastic composite component is lower than all the crystallization temperatures of one / the first thermoplastic resin of the first low-melting film, one / the second thermoplastic resin of the second low-melting film, the thermoplastic wing spar resin and the thermoplastic skin resin of the skin blank.

[0056] A1.9. The method according to any of paragraphs A1-A1.8, further comprising applying one / the second low-melt film on the first side of the skin blank.

[0057] A1.10. The method according to paragraph A1.9, wherein heating the skin blank includes heating the skin blank having the second low-melt film to a second temperature.

[0058] A1.11. A method according to paragraph A1.9 or A.10, wherein covering the skin blank includes covering the skin blank having the second low-melting film around the at least one tooling segment, so that the first side of the skin blank faces the outer surface of the at least one tooling segment, and at least a portion of the second low-melting film contacts the first low-melting film on the at least one interface surface.

[0059] A1.12. A method according to any of paragraphs A1.9-A1.11, wherein closing the punch includes closing the punch around the skin blank and the at least one tooling section, thereby pressing at least some of the second low-melting film against the first low-melting film on the at least one interface surface.

[0060] A1.13. The method of any of paragraphs A1.9-A1.12, wherein the second low-melting film comprises a second thermoplastic resin having a second film melting temperature that is lower than a spar melting temperature of a thermoplastic spar resin of the at least one spar.

[0061] A1.14. The method according to paragraph 1.13, wherein the second thermoplastic resin is the same as one of the first low-melting films / the first thermoplastic resin.

[0062] A2. The method of any of paragraphs A1-A1.14, further comprising molding the at least one spar.

[0063] A3. The method of paragraph A2, wherein forming the at least one spar comprises stamping the at least one spar.

[0064] A4. The method according to paragraph A3, wherein stamping and forming the at least one spar causes the first low-melting film to be applied to one / the outer surface of each flange of two opposing flanges of each spar of the at least one spar.

[0065] A4.1. The method of paragraph A3 or A4, wherein stamping the at least one spar causes the first low-melt film to be applied to at least one interface surface of the at least one spar.

[0066] A5. The method of any of paragraphs A1-A4.1, wherein the at least one tooling section comprises a first tooling section, and wherein loading the at least one spar comprises loading a first spar of the at least one spar on the first tooling section.

[0067] A6. The method of any of paragraphs A1-A5, wherein the at least one tooling section includes a second tooling section, and wherein loading the at least one spar includes loading a second spar of the at least one spar onto the second tooling section.

[0068] A7. A method according to any of paragraphs A1-A6, wherein loading at least one wing spar includes loading one / the second wing spar of the at least one wing spar onto one / the first tooling section.

[0069] A8. The method according to any of paragraphs A5-A7, further comprising bringing the first tooling section and one / the second tooling section together to close the first tooling section and the second tooling section together.

[0070] A9. The method of any of paragraphs A5-A8, wherein loading at least one spar comprises clamping the first spar between the first tooling section and a third tooling section.

[0071] A10. The method of any of paragraphs A5-A9, wherein loading at least one spar comprises clamping one / the second spar between the first tooling section and one / the second tooling section.

[0072] A11. A method according to any of paragraphs A5-A10, wherein loading at least one spar includes loading the first spar and one / the second spar so that a first channel of the first spar faces a second channel of the second spar.

[0073] A12. The method of any of paragraphs A5-A11, wherein one of the first spar / the first channel is engaged with the first tooling segment.

[0074] A13. The method of any of paragraphs A5-A12, wherein one / the second channel of one / the second spar is engaged with the first tooling section opposite the first spar.

[0075] A14. A method according to any of paragraphs A5-A13, wherein the at least one tooling segment includes multiple tooling segments, including one / the first tooling segment, one / the second tooling segment and / or one / the third tooling segment.

[0076] A15. The method of any of paragraphs A1-A14, further comprising actively cooling the at least one tooling segment.

[0077] A15.1. The method of any of paragraphs A1-A15, further comprising actively cooling one or more tools of the punch press.

[0078] A16. The method of any of paragraphs A1-A15.1, further comprising actively heating the at least one tooling segment.

[0079] A16.1. The method of any of paragraphs A1-A16, further comprising actively heating one or more tools of the punch press.

[0080] A17. A method according to any of paragraphs A1-A16.1, wherein the heating of the skin blank includes infrared heating.

[0081] A18. The method according to any of paragraphs A1-A17, wherein one / the second low-melting film is joined to the skin blank during the heating of the skin blank.

[0082] A19. The method of any of paragraphs A1-A18, further comprising positioning the skin blank and the at least one tooling segment relative to each other such that the skin blank is positioned above the at least one tooling segment.

[0083] A20. The method of any of paragraphs A1-A18, further comprising positioning the skin blank and the at least one tooling segment relative to each other so that they are side by side.

[0084] A21. The method according to any of paragraphs A1-A20, wherein covering the skin blank includes lowering the skin blank toward the at least one tooling section.

[0085] A22. The method according to any of paragraphs A1-A20, wherein covering the skin blank includes raising the at least one tooling segment toward the skin blank.

[0086] A23. The method according to any of paragraphs A1-A22, wherein covering the skin blank includes maintaining tension on the skin blank using a tensioning element during covering the skin blank.

[0087] A23.1. The method of paragraph A23, wherein the tensioning element comprises a clamp or a spring.

[0088] A24. The method of any of paragraphs A1-A23.1, further comprising trimming the fiber-reinforced thermoplastic composite component.

[0089] A25. The method of any of paragraphs A1-A24, further comprising nondestructively inspecting the fiber-reinforced thermoplastic composite component.

[0090] A26. The method according to any of paragraphs A1-A25, further comprising maintaining a predetermined pressure and / or temperature on the skin blank and the at least one tooling section after closing the punch, during the co-consolidation and before opening the punch.

[0091] A27. The method of any of paragraphs A1-A26, wherein the fiber-reinforced thermoplastic composite component is a closed-profile aerodynamic twist box.

[0092] A28. The method of any of paragraphs A1-A27, wherein closing the press comprises moving two halves of the press toward each other and toward at least one tooling segment.

[0093] A29. The method of any of paragraphs A1-A27, wherein closing the punch comprises moving a first half of the punch toward a second half of the punch.

[0094] A30. The method of any of paragraphs A1-A29, wherein closing the punch comprises moving the at least one tooling segment toward one / the second half of the punch using one / the first half of the punch.

[0095] A31. The method according to any of paragraphs A1-A30, comprising opening the punch press, wherein the opening of the punch press is performed after the fiber-reinforced thermoplastic composite component is below the film melting point of the first low-melting film and / or one / the second low-melting film.

[0096] A32. The method according to any one of paragraphs A1-A31, wherein the film melting point of the first low-melting film and / or one / the second low-melting film is lower than the skin melting point of the skin stock resin.

[0097] A33. A method according to paragraph A21, wherein the film melting point is at least 20 degrees Fahrenheit lower than the skin melting point, at least 30 degrees Fahrenheit lower than the skin melting point, at least 40 degrees Fahrenheit lower than the skin melting point, at least 50 degrees Fahrenheit lower than the skin melting point and / or at least 60 degrees Fahrenheit lower than the skin melting point.

[0098] A34. A method according to any of paragraphs A1-A33, wherein the heating of the skin blank is performed before closing the punch press.

[0099] A35. The method according to any one of paragraphs A1-A34, wherein covering the skin blank around the at least one tooling segment increases the film temperature of the first low-melting film to above the film melting point, thereby melting the first low-melting film.

[0100] A36. A method according to any of paragraphs A1-A35, wherein the fiber-reinforced thermoplastic composite component is a wingtip, a winglet, a rotor blade for an unmanned aerial vehicle (UAV), a rotor blade for a helicopter tail rotor, a wing, an aileron, a flap, a rudder and / or a smaller control surface of a UAV, helicopter or commercial aircraft.

[0101] A37. A method according to any of paragraphs A1-A36, wherein the at least one spar is a preformed spar.

[0102] A38. A method according to any of paragraphs A1-A37, wherein the punching machine includes one / the first half and one / the second half, the first half and the second half together forming a cavity, which is configured to receive a plurality of tooling segments, at least one interface surface of the at least one wing spar and the skin blank therein.

[0103] B1. A closed profile torsion box manufactured according to the method described in any of paragraphs A1-A38.

[0104] B2. Wingtips, winglets, rotor blades for unmanned aerial vehicles (UAVs), rotor blades for helicopter tail rotors, wings, ailerons, flaps, rudders and / or smaller control surfaces for UAVs, helicopters or commercial aircraft manufactured according to the method described in any of paragraphs A1-A38.

[0105] C1. A system for stamping a fiber-reinforced thermoplastic composite component, the system comprising:

[0106] a plurality of tooling sections configured to position at least one preformed spar for a stamping process;

[0107] an infrared heater configured to heat a fiber reinforced thermoplastic consolidated skin stock to a temperature above a skin melting point of a thermoplastic skin resin of the skin stock;

[0108] a tensioning element configured to maintain tension on the skin blank when the skin blank is wrapped around the plurality of tooling segments so that the skin blank faces an outer surface of the plurality of tooling segments; and

[0109] A punching machine is configured to close around the skin blank and the plurality of tooling segments, so that the punching machine is configured to press the skin blank onto the plurality of tooling segments and against the low-melting film on the at least one preformed spar, so that the skin blank and the at least one preformed spar are consolidated together to form the fiber-reinforced thermoplastic composite component.

[0110] C2. A system according to paragraph C1, wherein the stamping process includes the method described in any of paragraphs A1-A38.

[0111] C3. A system according to any of paragraphs C1-C2, wherein the low-melting film is applied to the outer surface of each flange of two opposing flanges of each spar of the at least one preformed spar.

[0112] C3.1. A system according to any of paragraphs C1-C3, wherein the low-melt film is applied to at least one interface surface of the at least one preformed spar.

[0113] C4. A system according to any of paragraphs C1-C3.1, wherein the plurality of tooling segments include a first tooling segment, a second tooling segment, and a third tooling segment, wherein the first tooling segment is configured to be positioned between the second tooling segment and the third tooling segment.

[0114] C5. The system of paragraph C4, wherein a first spar of the at least one preformed spar is configured to be loaded onto the plurality of tooling segments such that the first spar is sandwiched between the first tooling segment and the third tooling segment.

[0115] C6. A system according to any of paragraphs C4-C5, wherein a second spar of the at least one preformed spar is configured to be loaded onto the plurality of tooling segments such that the second spar is sandwiched between the first tooling segment and the second tooling segment.

[0116] C7. A system according to any of paragraphs C4-C6, wherein the plurality of tooling segments are configured to engage with each other and with the at least one preformed spar such that a first channel of one of the at least one preformed spar / the first spar faces a second channel of one of the at least one preformed spar / the second spar.

[0117] C8. A system according to any of paragraphs C1-C7, wherein the plurality of tooling segments are configured to position the at least one preformed spar so that outer surfaces of the opposing flanges of each respective spar face outward from outer surfaces of the plurality of tooling segments.

[0118] C8.1. A system according to any of paragraphs C1-C8, wherein the plurality of tooling segments are configured to position the at least one preformed spar so that at least one interface surface of each respective spar faces in a direction outward from an outer surface of the plurality of tooling segments.

[0119] C9. The system of any of paragraphs C1-C8.1, further comprising a cooling system configured to actively cool the plurality of tooling segments.

[0120] C10. The system of any of paragraphs C1-C79, further comprising a heating system configured to actively heat the plurality of tooling segments.

[0121] C11. A system according to any of paragraphs C1-C10, wherein the plurality of tooling segments are configured to move toward the skin stock when the skin stock is wrapped around the tooling segments.

[0122] C12. A system according to any of paragraphs C1-C11, wherein the punch is configured to maintain a predetermined pressure and / or temperature on the skin blank and the plurality of tooling segments for a period of time sufficient to consolidate the skin blank and the at least one preformed spar together.

[0123] C13. The system of any of paragraphs C1-C12, wherein the punch comprises a first half and a second half that together form a cavity configured to receive the plurality of tooling segments therein.

[0124] C14. The system of paragraph C13, wherein the first half and the second half are configured to move toward each other to close the punch around the plurality of tooling segments.

[0125] C15. The system of paragraph C13, wherein the first half is configured to move itself and the plurality of tooling segments toward the second half to close the punch around the plurality of tooling segments.

[0126] D1. Use of the system described in any of paragraphs C1-C15 to make a closed-profile torsion box.

[0127] D2. Use of a system according to any of paragraphs C1-C15 to manufacture wingtips, winglets, rotor blades for unmanned aerial vehicles (UAVs), rotor blades for helicopter tail rotors, wings, ailerons, flaps, rudders, and / or smaller control surfaces for UAVs, helicopters, or commercial aircraft.

[0128] As used herein, the terms "selective" and "selectively," when modifying an action, movement, configuration, or other activity of one or more components or features of a device, mean that the particular action, movement, configuration, or other activity is a direct or indirect result of a dynamic process and / or user operation of an aspect of the device or one or more components. Thus, the terms "selective" and "selectively" may characterize an activity that is a direct or indirect result of a user operation of an aspect of the device or one or more components, or may characterize a process that occurs automatically, such as by the mechanisms disclosed herein.

[0129] As used herein, the terms "suitable for" and "configured" refer to an element, component, or other subject matter that is designed and / or intended to perform a given function. Therefore, the use of the terms "suitable for" and "configured" should not be understood to mean that a given element, component, or other subject matter is simply "capable of" performing a given function, but rather should be understood to mean that the element, component, and / or other subject matter is selected, created, implemented, used, programmed, and / or designed specifically for performing that function. In addition, within the scope of the present disclosure, an element, component, and / or other described subject matter that is described as being suitable for performing a particular function may additionally or alternatively be described as being configured to perform that function, and vice versa. Similarly, a subject matter that is described as being configured to perform a particular function may additionally or alternatively be described as being operable to perform that function.

[0130] As used herein, the phrase "at least one", when referring to a list of one or more entities, should be understood as at least one entity selected from any one or more entities in the list of entities, but does not necessarily include at least one of each entity specifically listed in the list of entities, nor does it exclude any combination of entities in the list of entities. This definition also allows that in addition to the entities specifically identified in the list of entities referred to by the phrase "at least one", other entities may optionally be present, whether related or unrelated to those entities specifically identified. Thus, as a non-limiting example, "at least one of A and B" (or equivalently "at least one of A or B", or equivalently "at least one of A and / or B") may refer to at least one, optionally including more than one A, without B present (and optionally including entities other than B) in one instance; to at least one, optionally including more than one B, without A present (and optionally including entities other than A) in another instance; and to at least one, optionally including more than one A, and at least one, optionally including more than one B (and optionally including other entities) in still another instance. In other words, the phrases "at least one", "one or more", and "and / or" are open-ended expressions that can be either conjunctive or non-conjunctive in operation. For example, each of the expressions "at least one of A, B, and C", "at least one of A, B, or C", "one or more of A, B, and C", "one or more of A, B, or C", and "A, B, and / or C" can refer to A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B, and C together, and any of the above, optionally in combination with at least one other entity.

[0131] The elements of the various disclosed devices and the steps of the methods disclosed herein are not necessary according to all devices and methods of the present disclosure, and the present disclosure includes all novel and non-obvious combinations and sub-combinations of the various elements and steps disclosed herein. In addition, one or more of the various elements and steps disclosed herein may define independent creative subject matter, which is independent of and distinct from the entirety of the disclosed device or method. Therefore, such creative subject matter need not be associated with the specific devices and methods explicitly disclosed herein, and such creative subject matter may find use in devices and / or methods not explicitly disclosed herein.

[0132] As used herein, the phrase "for example," the phrase "as an example," and / or the simple term "example," when referring to one or more components, features, details, structures, examples, and / or methods according to the present disclosure, is intended to convey that the described components, features, details, structures, examples, and / or methods are illustrative, non-exclusive examples of components, features, details, structures, examples, and / or methods according to the present disclosure. Thus, the described components, features, details, structures, examples, and / or methods are not intended to be limiting, required, or exclusive / exhaustive; other components, features, details, structures, examples, and / or methods, including structurally and / or functionally similar and / or equivalent components, features, details, structures, examples, and / or methods, are also within the scope of the present disclosure.

Claims

1. A method (100) for stamping a fiber-reinforced thermoplastic composite component, the method (100) comprising: (102) applying a first low-melting film (16) to at least one interface surface (18) of at least one spar (10), wherein each spar (10) of the at least one spar (10) is formed of a fiber-reinforced thermoplastic composite material; (104) loading the at least one spar (10) onto at least one tooling section (20) such that the at least one interface surface (18) faces away from the at least one tooling section (20); (106) heating the at least one tooling section (20) to bring the first low-melting film (16) to a first temperature, wherein the first temperature is higher than a crystallization temperature of the first low-melting film (16), and wherein the first temperature is lower than a melting temperature of a thermoplastic spar resin of the at least one spar (10); (110) heating the skin blank (30) to a second temperature, wherein the second temperature is higher than the melting temperature of the thermoplastic skin resin of the skin blank (30), and wherein the skin blank (30) is a fiber-reinforced thermoplastic skin blank (30); (112) covering the skin blank (30) around the at least one tooling section (20) so that the first side (36) of the skin blank (30) faces the outer surface of the at least one tooling section (20); (114) closing the punch press (42) around the skin blank (30) and the at least one tooling section (20), thereby pressing the skin blank (30) into the at least one tooling section (20) and pressing the skin blank (30) against the first low-melting film (16) on the at least one interface surface (18); and (116) Consolidating the skin blank (30) and the at least one spar (10) together in the punch press (42) to form the fiber reinforced thermoplastic composite component.

2. The method (100) of claim 1, wherein the first low-melting film (16) comprises a first thermoplastic resin having a first film melting temperature, the first film melting temperature being lower than a spar melting temperature of the thermoplastic spar resin.

3. The method (100) of claim 1, wherein each spar (10) of the at least one spar (10) comprises an elongated portion (12) extending between two opposing flanges (14), and wherein the at least one interface surface (18) comprises an outer surface of each of the two opposing flanges (14) of the at least one spar (10).

4. The method (100) of claim 3, wherein (104) loading the at least one spar (10) onto the at least one tooling section (20) comprises loading the at least one spar (10) so that an outer surface of each of two opposing flanges (14) of the at least one spar (10) is exposed and faces away from the at least one tooling section (20).

5. The method (100) according to claim 1 further includes (118) opening the punch (42) to remove the fiber-reinforced thermoplastic composite component, wherein (118) opening the punch (42) is performed after the current temperature of the fiber-reinforced thermoplastic composite component is lower than the lowest temperature of the crystallization temperatures of the first thermoplastic resin of the first low-melting film (16), the second thermoplastic resin of the second low-melting film (34) on the skin blank (30), the thermoplastic wing spar resin and the thermoplastic skin resin of the skin blank (30).

6. The method (100) of claim 1, further comprising stamping the at least one spar (10), wherein stamping the at least one spar (10) causes the first low-melting film (16) to be applied to an outer surface of each of two opposing flanges (14) of each spar (10) of the at least one spar (10), and wherein the at least one interface surface (18) comprises an outer surface of each of two opposing flanges (14) of each spar (10) of the at least one spar (10).

7. The method (100) of claim 1, wherein the at least one tooling section (20) comprises a first tooling section (22), a second tooling section (24), and a third tooling section (26), wherein (104) loading the at least one spar (10) comprises: loading a first spar (10a) of the at least one spar (10) onto the first tooling section (22); Loading a second spar (10b) of the at least one spar (10) onto the first tooling section (22); The first tooling section (22) and the second tooling section (24) are brought together to close the first tooling section and the second tooling section (24), thereby clamping the second spar (10b) between the first tooling section (22) and the second tooling section (24); and The first spar (10a) is clamped between the first tooling section (22) and the third tooling section (26).

8. The method (100) of claim 1, wherein (104) loading the at least one spar (10) comprises loading a first spar (10a) of the at least one spar (10) and loading a second spar (10b) of the at least one spar (10) such that a first channel (50a) of the first spar (10a) faces a second channel (50b) of the second spar (10b), wherein the first channel (50a) of the first spar (10) engages with a first tooling section (22) of the at least one tooling section (20), and wherein the second channel (50b) of the second spar (10b) engages the first tooling section (22) opposite to the first spar (10a).

9. The method (100) of claim 1, wherein (110) heating the skin blank (30) comprises infrared heating.

10. The method (100) according to claim 1 further includes (108) applying a second low-melting film (34) on the first side (36) of the skin blank (30), wherein the second low-melting film (34) has been applied to the skin blank (30) before (110) heating the skin blank (30).

11. The method (100) of claim 1, wherein (112) covering the skin blank (30) includes maintaining tension on the skin blank (30) using a tensioning element (52) during (112) covering the skin blank (30).

12. The method (100) of claim 11, wherein the tensioning element (52) comprises a clamp or a spring.

13. The method (100) of claim 1, wherein the fiber reinforced thermoplastic composite component is a closed profile aerodynamic twist box.

14. The method (100) according to claim 1, wherein a film melting point of the first low-melting film (16) is lower than a skin melting point of the skin blank (30).

15. The method (100) according to claim 1, wherein (112) the skin blank (30) is covered around the at least one tooling section (20) to increase the film temperature of the first low-melting film (16) to above the film melting point, thereby melting the first low-melting film (16).

16. The method (100) of claim 1, wherein the at least one spar (10) is a preformed spar (10).

17. A closed profile torsion box, wherein the closed profile torsion box comprises one or more selected from the group consisting of a wing tip, a winglet, a rotor blade for an unmanned aerial vehicle (UAV), a rotor blade for a helicopter tail rotor, a wing, an aileron, a flap, a rudder, and a smaller control surface for a UAV, a helicopter, or a commercial aircraft, and wherein the closed profile torsion box is manufactured according to a method (100), comprising: (102) applying a first low-melting film (16) to at least one interface surface (18) of at least one spar (10), wherein each spar (10) of the at least one spar (10) is formed of a fiber-reinforced thermoplastic composite material; (104) loading the at least one spar (10) onto at least one tooling section (20) such that the at least one interface surface (18) faces away from the at least one tooling section (20); (106) heating the at least one tooling section (20) to bring the first low-melting film (16) to a first temperature, wherein the first temperature is higher than a crystallization temperature of the first low-melting film (16), and wherein the first temperature is lower than a melting temperature of a thermoplastic spar resin of the at least one spar (10); (110) heating the skin blank (30) to a second temperature, wherein the second temperature is higher than the melting temperature of the thermoplastic skin resin of the skin blank (30), and wherein the skin blank (30) is a fiber-reinforced thermoplastic skin blank (30); (112) covering the skin blank (30) around the at least one tooling section (20) so that the first side (36) of the skin blank (30) faces the outer surface of the at least one tooling section (20); (114) closing the punch press (42) around the skin blank (30) and the at least one tooling section (20), thereby pressing the skin blank (30) into the at least one tooling section (20) and pressing the skin blank (30) against the first low-melting film (16) on the at least one interface surface (18); and (116) Consolidating the skin blank (30) and the at least one spar (10) together within the stamping press (42) to form the closed profile torsion box.

18. A system (60) for stamping a fiber reinforced thermoplastic composite component, the system (60) comprising: a plurality of tooling sections (12) configured to position at least one preformed spar (10) for a stamping process; an infrared heater (38) configured to heat the fiber-reinforced thermoplastic consolidated skin blank (30) to a temperature higher than a film melting point of a first low-melting film (16) applied to the at least one preformed spar (10); A tensioning element (52) configured to maintain tension on the skin blank (30) when the skin blank (30) is wrapped around the plurality of tooling segments (20) so that the skin blank (30) faces the outer surface of the plurality of tooling segments (20); and A punching machine (42) is configured to close around the skin blank (30) and the plurality of tooling segments (20), so that the punching machine (42) is configured to press the skin blank (30) onto the plurality of tooling segments (20) and press against the first low-melting film (16) on the at least one preformed spar (10), so that the skin blank (30) and the at least one preformed spar (10) are jointly consolidated to form the fiber-reinforced thermoplastic composite component.

19. The system (60) of claim 18, wherein the plurality of tooling sections (20) include a first tooling section (22), a second tooling section (24), and a third tooling section (26), wherein the first tooling section (22) is configured to be positioned between the second tooling section (24) and the third tooling section (26), wherein a first spar (10a) of the at least one preformed spar (10) is configured to be loaded onto the plurality of tooling sections (20) such that the first spar (10) is sandwiched between the first tooling section (22) and the third tooling section (26). The plurality of tooling sections (20) are configured to position the at least one preformed spar (10) such that at least one interface surface (18) of each respective spar (10) faces in a direction outward from an outer surface of the plurality of tooling sections (20).

20. The system (60) of claim 18, further comprising: a cooling system (62) configured to actively cool the plurality of tooling segments (20); and A heating system (64) is configured to actively heat the plurality of tooling segments (20).

Images