Patent Publication Number: US-2019184646-A1

Title: System and method of constructing a thermoplastic component

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     Not applicable. 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not applicable. 
     BACKGROUND 
     Structural components in aircraft are often subjected to high forces and/or loads when in motion. In some instances, structural aircraft components are subjected to occasional impact from objects. These structural components must be designed to be lightweight while handling the forces and resisting impact damage. Accordingly, structural aircraft components are frequently constructed from a core having a matrix of adjoining hollow cells and an attached outer skin to maintain structural integrity of the components while also minimizing weight. Current systems and methods for constructing such structural aircraft components include using a fiber-reinforced thermoset skin bonded to a fiber-reinforced thermoset core. However, these thermoset components present many challenges, such as requiring complex surface preparation procedures prior to bonding, which can leave the bonds predisposed to failure if not performed properly. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a more complete understanding of the present disclosure and the advantages thereof, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description. 
         FIG. 1  is a schematic diagram of a process of joining a thermoplastic skin and a thermoplastic core having similar properties according to this disclosure. 
         FIG. 2  is a schematic diagram of a process of joining a thermoplastic skin and a thermoplastic core having dissimilar properties according to this disclosure. 
         FIG. 3  is a schematic diagram of a process of joining a thermoplastic skin and a thermoplastic core having similar properties using a thermoplastic film according to this disclosure. 
         FIG. 4  is a schematic diagram of a process of joining a thermoplastic skin and a thermoplastic core having dissimilar properties using a thermoplastic film according to this disclosure. 
         FIG. 5  is a schematic diagram of a two-step process of joining a thermoplastic skin and a thermoplastic core using a thermoplastic film according to this disclosure. 
         FIG. 6  is a schematic diagram of another two-step process of joining a thermoplastic skin and a thermoplastic core using a thermoplastic film according to this disclosure. 
         FIG. 7  is a schematic diagram of yet another two-step process of joining a thermoplastic skin and a thermoplastic core using a thermoplastic film according to this disclosure. 
         FIG. 8  is a schematic diagram of a process of emulating reticulation in a thermoplastic core according to this disclosure. 
         FIG. 9  is a schematic diagram of the emulated reticulation in a thermoplastic core according to this disclosure. 
         FIG. 10  is an oblique view of a portion of a thermoplastic core according to this disclosure. 
         FIG. 11  is a schematic diagram of a helicopter according to this disclosure. 
         FIG. 12  is a schematic diagram of a tiltrotor according to this disclosure. 
         FIG. 13  is a flowchart of a method of constructing a thermoplastic component according to this disclosure. 
         FIG. 14  is a flowchart of another method of constructing a thermoplastic component according to this disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     In this disclosure, reference may be made to the spatial relationships between various components and to the spatial orientation of various aspects of components as the devices are depicted in the attached drawings. However, as will be recognized by those skilled in the art after a complete reading of this disclosure, the devices, members, apparatuses, etc. described herein may be positioned in any desired orientation. Thus, the use of terms such as “above,” “below,” “upper,” “lower,” or other like terms to describe a spatial relationship between various components or to describe the spatial orientation of aspects of such components should be understood to describe a relative relationship between the components or a spatial orientation of aspects of such components, respectively, as the device described herein may be oriented in any desired direction. 
     This invention relates generally to constructing a thermoplastic component. More specifically, this disclosure relates to constructing a thermoplastic component by adhering a fiber-reinforced thermoplastic skin to a fiber-reinforced thermoplastic core. Thermoplastics, by definition, rely on a phase-change when processed by melting and re-solidifying upon cooling. Thermoplastic materials begin in a first solid state that is melted into a second semi-liquid or liquid state, consolidated with another component, and then re-solidified when cooled to create a single “welded,” “melt-bonded,” and/or “fusion-bonded” thermoplastic component. As such, constructing a thermoplastic component in accordance with this disclosure requires melting a surface and/or surface element of each of thermoplastic skin and a thermoplastic core at an interface between the two, consolidating the skin and core at the interface via contact and/or an application of pressure, and then cooling the skin and core at the interface to create the single unitary thermoplastic component. 
     Referring now to  FIG. 1 , a schematic diagram of a process  100  of joining a thermoplastic skin  102  and a thermoplastic core  104  having similar properties is shown according to this disclosure. Thermoplastic skin  102  and thermoplastic core  104  may generally be formed from a fiber-reinforced thermoplastic material and comprise substantially similar material properties (e.g. composition, strength, melting temperature, etc.). In this embodiment, thermoplastic skin  102  and thermoplastic core  104  comprise a substantially similar melting temperature. To begin process  100 , a heat source  106  is employed to selectively apply heat  108  to an interface  103  of the thermoplastic skin  102  and/or an interface  105  of the thermoplastic core  104  to cause the thermoplastic skin  102  and the thermoplastic core  104  to melt at their respective interfaces  103 ,  105 . 
     In some embodiments, heat source  106  may comprise a vibratory mechanism that selectively vibrates at least one of the thermoplastic skin  102  and the thermoplastic core  104  to generate heat  108  via friction between the interfaces  102 ,  104 . To generate heat  108  through friction, it will be appreciated that the interfaces  103 ,  105  are in contact prior to the heat source  106  applying the vibration. In other embodiments, heat source  106  may be configured to generate inductive heat  108 , radiant heat  108 , and/or any other type of heat  108  to melt the thermoplastic skin  102  and the thermoplastic core  104  to melt at their respective interfaces  103 ,  105 . Accordingly, in some embodiments, the interfaces  103 ,  105  may be in contact prior to applying the inductive, radiant, and/or other type of heat  108 . However, in some embodiments, the interfaces  103 ,  105  may be separated prior to application of the inductive, radiant, and/or other type of heat  108 . 
     When inductive, radiant, and/or other type of heat  108  is employed, the heat  108  may be directed onto the interfaces  103 ,  105  from the top, bottom, and/or sides of the thermoplastic skin  102  and/or the thermoplastic core  104  until each of the interfaces  103 ,  105  reaches its melting temperature. By directing the heat  108  at the interfaces  103 ,  105 , the structure of the thermoplastic skin  102  and the thermoplastic core  104  maintain their structural integrity. The heat  108  transfers sufficient energy to bring the interfaces  103 ,  105  to the melting temperature and at least partially melt the thermoplastic skin  102  and the thermoplastic core  104  at their respective interfaces  103 ,  105 . As the interfaces  103 ,  105  at least partially melt, the interfaces  103 ,  105  of the thermoplastic skin  102  and the thermoplastic core  104  undergo a phase-change from a solid to liquid. In one example, the interfaces  103 ,  105  may be subjected to heat  108  and begin to soften at about 360 to 380 degrees Fahrenheit. Each of the interfaces  103 ,  105 , may continue to soften until the temperature reaches about 600 degrees Fahrenheit, at which temperature each of the interfaces  103 ,  105  is considered fully melted. 
     To reach the fully melted state of the interfaces  103 ,  105 , the heating rate at the interfaces  103 ,  105  must be sufficiently rapid to ensure that the structure and stiffness of a majority of the thermoplastic skin  102  and thermoplastic core  104  retain their shapes and structural integrity such that melting only occurs at the interfaces  103 ,  105 . Then, upon reaching the fully melted state, the thermoplastic skin  102  and the thermoplastic core  104  are consolidated by forcing the thermoplastic skin  102  and the thermoplastic core  104  into contact through gravity, pressure, and/or another external force. However, in embodiments where the thermoplastic skin  102  and thermoplastic core  104  are in contact prior to applying heat  108 , the interfaces  103 ,  105  may consolidate automatically. Consolidation occurs when the melted interfaces  103 ,  105  remain in contact and re-solidify upon cooling. In some embodiments, the interfaces  103 ,  105  may be allowed to cool naturally at room temperature by selectively ceasing the application of heat  108  to the interfaces  103 ,  105 . However, in some embodiments, a thermal mass having high thermal conductivity (e.g. aluminum) may be applied to the thermoplastic component  120 . The thermal mass may quickly extract heat from the thermoplastic component  120 , which may further retain the integrity and/or structure of thermoplastic core  104 . 
     Upon consolidation, the interfaces  103 ,  105  undergo a second phase-change, changing from a liquid to a solid, re-solidifying and recrystallizing and/or reorganizing to form a single “welded” and/or “fusion-bonded” unitary thermoplastic component  120 . Accordingly, the thermoplastic skin  102  and the thermoplastic core  104  are joined by the welding and/or fusion-bonding process that requires no adhesive. The interfaces  103 ,  105  of the thermoplastic skin  102  and the thermoplastic core  104  are simply melted, consolidated, and then cooled to form the thermoplastic component  120 . By eliminating the need for adhesive to form the bond between the thermoplastic skin  102  and the thermoplastic core  104 , costly and complex surface preparation procedures necessary in bonding thermoset components are eliminated. Further, the reticulation formed by thermoset components is also emulated through process  100 . Additionally, it will be appreciated that fiber-reinforced thermoplastic components  120  exhibit improved damage tolerance, better strength after impact, and other structurally desirable characteristics as compared to most current thermoset components. 
     Referring now to  FIG. 2 , a schematic diagram of a process  200  of joining a thermoplastic skin  202  and a thermoplastic core  204  having dissimilar properties is shown according to this disclosure. Process  200  may be substantially similar to process  100  and used to join thermoplastic skin  202  to thermoplastic core  204  to form a thermoplastic component  220  in a substantially similar manner to process  100 . However, thermoplastic skin  202  comprises dissimilar properties from thermoplastic core  204 . In some embodiments, thermoplastic skin  202  comprises a fiber-reinforced thermoplastic material having a slightly lower melting temperature than the thermoplastic core  204 . Accordingly, when heat  208  is applied from heat source  206 , interface  203  of the thermoplastic skin  202  reaches its melting temperature prior to interface  205  reaching its melting temperature. 
     In some embodiments, thermoplastic skin  202  may generally be formed from a fiber-reinforced thermoplastic material that is impregnated with a constituent  207  that enhances heat transfer between the heat source  206  and the thermoplastic skin  202 . Constituent  207  comprises an interspersed metallic component and/or other material component that enhances heat transfer by more readily responding to inductive, radiant, and other type of heat  208 . Accordingly, when heat  208  is applied from heat source  206 , constituent  207  allows the interface  203  of the thermoplastic skin  202  to reach its melting temperature prior to the interface  205  of the thermoplastic core  204  reaching its melting temperature. The material of the thermoplastic skin  202  may be selected, designed, and/or otherwise impregnated with constituent  207  such that the interface  203  of the thermoplastic skin  202  reaches its melting temperature just prior to that of the interface  205  of the thermoplastic core  204 . This lowers the risk of the thermoplastic core  204  receiving too much heat  208 , thereby protecting and preserving the structural integrity of the thermoplastic core  204  when heat  208  is applied to join the thermoplastic skin  202  and the thermoplastic core  204 . 
     Referring now to  FIG. 3 , a schematic diagram of a process  300  of joining a thermoplastic skin  302  and a thermoplastic core  304  having similar properties using a thermoplastic film  310  is shown according to this disclosure. Process  300  may be substantially similar to process  100  and used to join thermoplastic skin  302  to thermoplastic core  304  to form a thermoplastic component  320  in a substantially similar manner to process  100 . However, process  300  utilizes thermoplastic film  310  disposed between interfaces  303 ,  305  of the thermoplastic skin  302  and thermoplastic core  304  and configured to join the thermoplastic skin  302  and the thermoplastic core  304  to form the thermoplastic component  320 . In some embodiments, thermoplastic film  310  comprises a thermoplastic material comprising a substantially similar melting temperature to that of the thermoplastic skin  302  and thermoplastic core  304 . However, in some embodiments, thermoplastic film  310  comprises a thermoplastic material comprising a slightly lower melting temperature than the thermoplastic skin  302  and thermoplastic core  304 . 
     To join the thermoplastic skin  302  to the thermoplastic core  304 , heat  308  may be directed to the thermoplastic film  310  while also directed heat  308  to the interfaces  303 ,  305 . When fully melted, the thermoplastic film  310  may flow between the at least partially melted interfaces  303 ,  305 . The thermoplastic skin  310  may be sandwiched between the thermoplastic skin  302  and the thermoplastic core  104  by forcing the thermoplastic skin  102  and the thermoplastic core  104  into contact through gravity, pressure, and/or another external force. Upon cooling, the thermoplastic film  310  joins the thermoplastic skin  102  and the thermoplastic core  104  by the welding and/or fusion-bonding provided by the thermoplastic film  310 , thereby forming the thermoplastic component  320 . Similarly to processes  100 , process  300  eliminates the need for adhesive and the costly and complex surface preparation procedures necessary in bonding thermoset components. 
     Referring now to  FIG. 4 , a schematic diagram of a process  400  of joining a thermoplastic skin  402  and a thermoplastic core  404  having dissimilar properties using a thermoplastic film  410  is shown according to this disclosure. Process  400  may be substantially similar to process  300  and used to join thermoplastic skin  402  to thermoplastic core  404  to form a thermoplastic component  420  in a substantially similar manner to process  300 . However, thermoplastic film  410  comprises dissimilar properties from thermoplastic skin  402  and thermoplastic core  404 . In some embodiments, thermoplastic film  410  comprises a fiber-reinforced thermoplastic material, the thermoplastic portion having a lower melting temperature than the thermoplastic skin  402  and thermoplastic core  404 . Accordingly, when heat  408  is applied from heat source  406 , thermoplastic film  410  reaches its melting temperature prior to interfaces  403 ,  405  reaching their melting temperatures. 
     In some embodiments, thermoplastic film  410  may generally be formed from a fiber-reinforced thermoplastic material that is impregnated with a constituent  407  substantially similar to constituent  207  that enhances heat transfer between the heat source  406  and the thermoplastic film  410 . Constituent  407  may comprise an interspersed metallic component and/or other material component that enhances heat transfer by more readily responding to inductive, radiant, and other type of heat  408 . However, in some embodiments, constituent  407  may be configured to react to an induced electromagnetic field (EMF). Accordingly, when heat  408  is applied from heat source  406 , constituent  407  allows the thermoplastic film  410  to reach its melting temperature prior to the interfaces  403 ,  405  reaching its melting temperature. The material of the thermoplastic film  410  may therefore be selected, designed, and/or otherwise impregnated with constituent  407  such that the thermoplastic film  410  reaches its melting temperature just prior to that of the interfaces  403 ,  405 . This lowers the risk of the thermoplastic skin  402  and the thermoplastic core  404  receiving too much heat  408 , thereby protecting and preserving the structural integrity of the thermoplastic core  404  when heat  408  is applied to join the thermoplastic skin  202  and the thermoplastic core  404  and form the thermoplastic component  420 . 
     Referring now to  FIG. 5 , a schematic diagram of a two-step process  500  of joining a thermoplastic skin  502  and a thermoplastic core  504  using a thermoplastic film  510  is shown according to this disclosure. Process  500  may be substantially similar to processes  300 ,  400  and used to join thermoplastic skin  502  to thermoplastic core  504  to form a thermoplastic component  520  in a substantially similar manner to processes  300 ,  400 . However, process  500  involves multiple steps to form the thermoplastic component  520 . In a first step, heat  508  is applied by the heat source  506  to the thermoplastic film  510  and interface  505  of the thermoplastic core  504 , whereby the thermoplastic film  510  is joined to the thermoplastic core  504  in accordance with techniques described in this disclosure to form an intermediate thermoplastic component  519 . In a second step, heat  508  is applied to the thermoplastic film  510  and interface  503  of the thermoplastic skin  502 , whereby the thermoplastic skin  502  is joined to the intermediate thermoplastic component  519  in accordance with techniques described in this disclosure to form the thermoplastic component  520 . 
     Referring now to  FIG. 6 , a schematic diagram of another two-step process  600  of joining a thermoplastic skin  602  and a thermoplastic core  604  using a thermoplastic material  610  is shown according to this disclosure. Process  600  may be substantially similar to process  500  and used to join thermoplastic skin  602  to thermoplastic core  604  to form a thermoplastic component  620  in a substantially similar manner to process  500 . However, in a first step of process  600 , thermoplastic core  604  is dipped into a melted, liquid-state thermoplastic material  610 . In some embodiments, thermoplastic material  610  may be carried by a vessel  611  and melted by applying heat  608  from heat source  606 . However, in other embodiments, vessel  611  may be heated by the heat source  606  to melt the thermoplastic material  610  prior to dipping the thermoplastic core  604  into the melted thermoplastic material  610 . When the thermoplastic core  604  is dipped into the melted thermoplastic material  610 , the interface  605  of the thermoplastic core  604  is coated with the melted thermoplastic material  610 , and when cooled, the thermoplastic core  604  and the thermoplastic material  610  form intermediate thermoplastic component  619 . Thus, similarly to process  500 , in a second step of process  600 , heat  608  is applied to the thermoplastic material  610  and interface  603  of the thermoplastic skin  602 , whereby the thermoplastic skin  602  is joined to the intermediate thermoplastic component  619  in accordance with techniques described in this disclosure to form the thermoplastic component  620 . 
     Referring now to  FIG. 7 , a schematic diagram of yet another two-step process  700  of joining a thermoplastic skin  702  and a thermoplastic core  704  using a thermoplastic film is shown according to this disclosure. Process  700  may be substantially similar to process  400 ,  500  and used to join thermoplastic skin  702  to thermoplastic core  704  to form a thermoplastic component  720  in a substantially similar manner to processes  400 ,  500 . However, thermoplastic film  710  is formed from a fiber-reinforced thermoplastic material that comprises constituent  707 . Constituent  707  may comprise an interspersed electrically conductive and/or resistive component and be configured to conduct electrical current to induce heat  708  into the thermoplastic skin  710 . When a current is applied to the thermoplastic skin  710  by the heat source  706 , the constituents  707  in the thermoplastic skin generate sufficient heat to melt the thermoplastic skin  710 . 
     Accordingly, in a first step of process  700 , the thermoplastic skin  710  is joined to the thermoplastic core  704  to form an intermediate thermoplastic component  719 . In a second step of process  700 , the thermoplastic skin  702  is joined to the intermediate thermoplastic component  719 . However, in alternative embodiments, the thermoplastic skin  702  and the thermoplastic core  704  may be joined in a single step substantially similar to process  400 . The material of the thermoplastic film  710  may therefore be selected, designed, and/or otherwise impregnated with constituent  707  such that the thermoplastic film  710  reaches its melting temperature just prior to that of the interfaces  703 ,  705 . This lowers the risk of the thermoplastic skin  702  and the thermoplastic core  704  receiving too much heat  708 , thereby protecting and preserving the structural integrity of the thermoplastic core  704  when heat  708  is applied to the interfaces  703 ,  705  to join the thermoplastic skin  702  and the thermoplastic core  704  and form the thermoplastic component  720 . 
     Referring now to  FIGS. 8 and 9 , a schematic diagram of a process  800  of emulating reticulation in a thermoplastic core  804  and a schematic diagram of the emulated reticulation in a thermoplastic core  804  are shown, respectively, according to this disclosure. Process  800  comprises employing a heat source  806  having a flat and/or other complementary-shaped surface and raising the surface temperature above a melting temperature of the thermoplastic core  804 . The heat source  806  is selectively moved into contact with an interface  805 ′ of the thermoplastic core  804 . Pressure is then applied to the thermoplastic core  804  by the heat source  806  to heat the thermoplastic core  804  at the interface  805 ′, thereby at least partially melting the interface  805 ′ of the thermoplastic core  804 . As pressure is applied to the melted interface  805 ′, the edges of the interface  805 ′ are slightly crushed, smashed, and/or otherwise deformed, while the remainder of the thermoplastic core  804  maintains its structural integrity. In some embodiments, interface  805 ′ may be smashed about 0.5 to about 1.0 millimeters. The interface  805 ′ may then be cooled, and pressure from the heat source  806  is relieved as the heat source  806  is removed from contact with the thermoplastic core  804 , and the result of the deformation of the interface  805 ′ is a compressed interface  805 ″ that comprises a larger surface area as compared to the uncrushed interface  805 ′. As such, it will be appreciated that compressed interface  805 ″ may be formed via crushing, folding, deforming, causing an accordion-like collapsing, twisting, and/or any other natural deformative process caused by the application of heat and pressure. Furthermore, it will be appreciated that increased amount of heat and/or pressure may result in an increased surface area of the compressed interface  805 ″, and heat and pressure may be controlled to produce a compressed interface  805 ″ having a specific surface area across the thermoplastic core  804 . 
     The compressed interface  805 ″ thereby emulates the reticulation caused by surface tension in current thermoset components that employ adhesive between a skin and core and/or aluminum crushed core components. Thus, only the interface  805 ′ is compressed to form the compressed interface  805 ″, while the remainder of the thermoplastic core  804  retains its structural integrity. Further, it will be appreciated that thermoplastic core  804  may be representative of thermoplastic cores  104 ,  204 ,  304 ,  404 ,  504 ,  607 ,  704 . Additionally, the compressed interface  805 ″ creates a larger footprint than other non-crushed portions of the thermoplastic core  804  for an increased surface contact area between the thermoplastic core  804  and a subsequent thermoplastic skin  102 ,  202 ,  302 ,  402 ,  502 ,  602 ,  702  that may be joined thereto. The compressed interface  805 ″ created by process  800  thus strengthens the joint between a thermoplastic core  104 ,  204 ,  304 ,  404 ,  504 ,  604 ,  704 ,  804  and a thermoplastic skin  102 ,  202 ,  302 ,  402 ,  502 ,  602 ,  702  and/or an optional thermoplastic film  310 ,  410 ,  510 ,  610 ,  710 . Accordingly, process  800  may be used prior to any of processes  100 ,  200 ,  300 ,  400 ,  500 ,  600 ,  700  to form a compressed interface  805 ″ on the thermoplastic cores  104 ,  204 ,  304 ,  404 ,  504 ,  607 ,  704 . 
     Furthermore, while processes  100 ,  200 ,  300 ,  400 ,  500 ,  600 ,  700 ,  800  are described in terms of applying a single thermoplastic skin  102 ,  202 ,  302 ,  402 ,  502 ,  602 ,  702  to a thermoplastic core  104 - 804 , it will be appreciated that multiple thermoplastic skins  102 ,  202 ,  302 ,  402 ,  502 ,  602 ,  702  and/or thermoplastic films  310 ,  410 ,  510 ,  610 ,  710  may be applied to a thermoplastic core  104 ,  204 ,  304 ,  404 ,  504 ,  607 ,  704 ,  804 . Further it will be appreciated that multiple thermoplastic skins  102 ,  202 ,  302 ,  402 ,  502 ,  602 ,  702  and/or thermoplastic films  310 ,  410 ,  510 ,  610 ,  710  to substantially encapsulate the thermoplastic core  104 ,  204 ,  304 ,  404 ,  504 ,  604 ,  704 ,  804  to form a thermoplastic component  120 ,  220 ,  320 ,  420 ,  520 ,  620 ,  720 . 
     Referring now to  FIG. 10 , an oblique view of a portion of a thermoplastic core  900  is shown according to this disclosure. Thermoplastic core  900  is generally formed from a plurality of thin thermoplastic components  902 ,  904 ,  906 ,  910  to form a matrix of adjoining and adjacently-disposed hollow cells  910  comprising an interface  912  substantially similar to interfaces  105 ,  205 ,  305 ,  405 ,  505 ,  605 ,  705 ,  805 ′ and can be used in process  800  to form a compressed interface  805 ″. Thermoplastic core  900  generally comprises honeycomb-shaped cells  910 . However, in other embodiments, thermoplastic core  900  may comprise any other shaped (e.g. round, rectangular, octagonal) cells  910 . Thermoplastic core  900  generally comprises a large cell thermoplastic core (LCTC) that is representative of thermoplastic cores  104 ,  204 ,  304 ,  404 ,  504 ,  604 ,  704 ,  804  used to construct thermoplastic components  120 ,  220 ,  320 ,  420 ,  520 ,  620 ,  720 . Large cells  910  afford the thermoplastic core  900  increased performance characteristics to shear energy as opposed to small cell cores. Large cells  910  in thermoplastic core  900  also allow the structural response of the thermoplastic component  120 ,  220 ,  320 ,  420 ,  520 ,  620 ,  720  to be tailored to a specific application and optimizes energy transfer between skins  102 ,  202 ,  302 ,  402 ,  502 ,  602 ,  702 . Additionally, large cells  910  increase the importance of reticulation in the cell, thereby forming a compressed interface  805 ″ on interface  912  is imperative to optimizing performance. However, it will be appreciated that the size and shape of the thermoplastic components  902 ,  904 ,  906 ,  908  and/or the cells  910  may be selected based on a specific application. 
     Referring now to  FIG. 11 , a schematic diagram of a helicopter  1000  is shown according to this disclosure. Helicopter  1000  comprises a fuselage  1002 , an empennage  1004  having a tail rotor  1010 , and a rotor system  1006  comprising a plurality of rotor blades  1008 . It will be appreciated that processes  100 - 800  may be used to form a thermoplastic component  120 ,  220 ,  320 ,  420 ,  520 ,  620 ,  720  that may be used in the fuselage  1002 , empennage  1004 , rotor blades  1008 , and/or tail rotor  1010  of helicopter  1000 . 
     Referring now to  FIG. 12 , a schematic diagram of a tiltrotor  1100  is shown according to this disclosure. Tiltrotor  1100  comprises a fuselage  1102  with attached wings  1104 . Pylons  1106  are disposed at the outboard ends of the wings  1104  and are rotatable between a helicopter mode (shown) and a forward-flight airplane mode (not shown). Each pylon  1106  comprises a rotor system  1108  comprising a plurality of rotor blades  1110 . It will be appreciated that processes  100 - 800  may be used to form a thermoplastic component  120 ,  220 ,  320 ,  420 ,  520 ,  620 ,  720  that may be used in the fuselage  1102 , wings  1104 , and/or rotor blades  1110  of tiltrotor  1100 . 
     Furthermore, in some embodiments, processes  100 ,  200 ,  300 ,  400 ,  500 ,  600 ,  700 ,  800  may be used to construct components  120 ,  220 ,  320 ,  420 ,  520 ,  620 ,  720  of military vehicles and sea craft, commercial and/or residential buildings, and/or any other structures or components. The large cell thermoplastic core  900  used to form thermoplastic components  120 ,  220 ,  320 ,  420 ,  520 ,  620 ,  720  comprises increased strength both before and after impact as compared to thermoset components. Further, the large cell thermoplastic core  900  used to form thermoplastic components  120 ,  220 ,  320 ,  420 ,  520 ,  620 ,  720  will not propagate in high cycle fatigue applications. As such, the thermoplastic components  120 ,  220 ,  320 ,  420 ,  520 ,  620 ,  720  may be used in high-energy dissipating materials or structures that are prone to impact such as leading edges of rotor blades  1008 ,  1110 , tail rotors  1010 , and wings  1104 , other flight control surfaces of a helicopter  1000 , tiltrotor  1110  and/or other aircraft, and/or a fuselage  1002 ,  1102  of an aircraft  1000 ,  1100  that are subject to impact damage. 
     Referring now to  FIG. 13 , a flowchart of a method  1200  of constructing a thermoplastic component  120 ,  220 ,  320 ,  420 ,  520 ,  620 ,  720  is shown according to this disclosure. Method  1200  begins at block  1202  by providing a thermoplastic skin  102 ,  202 ,  302 ,  402 ,  502 ,  602 ,  702  and a thermoplastic core  104 ,  204 ,  34 ,  404 ,  504 ,  604 ,  704 ,  804 . Method  1200  continues at block  1204  by heating an interface  103 ,  203 ,  303 ,  403 ,  503 ,  603 ,  703  of the thermoplastic skin  102 ,  202 ,  302 ,  402 ,  502 ,  602 ,  702  and an interface  105 ,  205 ,  305 ,  405 ,  505 ,  605 ,  705 ,  805 ″ of the thermoplastic core  104 ,  204 ,  304 ,  404 ,  504 ,  604 ,  704 ,  804 . Method  1200  continues at block  1206  by applying pressure to at least one of the thermoplastic skin and the thermoplastic core to make contact between the interfaces  103 ,  203 ,  303 ,  403 ,  503 ,  603 ,  703 , and  105 ,  205 ,  305 ,  405 ,  505 ,  605 ,  705 ,  805 ″. Method  1200  concludes at block  1208  by cooling the interfaces  103 ,  203 ,  303 ,  403 ,  503 ,  603 ,  703  and  105 ,  205 ,  305 ,  405 ,  505 ,  605 ,  705 ,  805 ″ below the melting point of each of the thermoplastic skin  102 ,  202 ,  302 ,  402 ,  502 ,  602 ,  702  and the thermoplastic core  104 ,  204 ,  304 ,  404 ,  504 ,  604 ,  704 ,  804  to consolidate the thermoplastic skin  102 ,  202 ,  302 ,  402 ,  502 ,  602 ,  702  and the thermoplastic core  104 ,  204 ,  304 ,  404 ,  504 ,  604 ,  704 ,  804  into a unitary thermoplastic component  120 ,  220 ,  320 ,  420 ,  520 ,  620 ,  720 . 
     Referring now to  FIG. 14 , a flowchart of another method  1300  of constructing a thermoplastic component is shown according to this disclosure. Method  1300  begins at block  1302  by providing a thermoplastic skin  102 ,  202 ,  302 ,  402 ,  502 ,  602 ,  702 , a thermoplastic core  104 ,  204 ,  304 ,  404 ,  504 ,  604 ,  704 ,  804 , and a thermoplastic film  310 - 710 . Method  1300  continues at block  1304  by heating the thermoplastic film  310 ,  410 ,  510 ,  610 ,  710  and an interface  105 ,  205 ,  305 ,  405 ,  505 ,  605 ,  705 ,  805 ″ of the thermoplastic core  104 ,  204 ,  304 ,  404 ,  504 ,  604 ,  704 ,  804 . Method  1300  continues at block  1306  by heating the thermoplastic film  310 ,  410 ,  510 ,  610 ,  710  and an interface  103 ,  203 ,  303 ,  403 ,  503 ,  603 ,  703  of the thermoplastic skin  102 ,  202 ,  302 ,  402 ,  502 ,  602 ,  702 . In some embodiments, the thermoplastic film  310 ,  410 ,  510 ,  610 ,  710  and the interface  105 ,  205 ,  305 ,  405 ,  505 ,  605 ,  705 ,  805 ″ of the thermoplastic core  104 ,  204 ,  304 ,  404 ,  504 ,  604 ,  704 ,  804  may be cooled prior to continuing at block  1306 . However, in other embodiments, blocks  1304  and  1306  may be accomplished simultaneously. 
     Method  1300  continues as block  1308  by applying pressure to at least one of the thermoplastic skin  102 ,  202 ,  302 ,  402 ,  502 ,  602 ,  702  and the thermoplastic core  104 ,  204 ,  304 ,  404 ,  504 ,  604 ,  704 ,  804  to make contact between the thermoplastic film  310 ,  410 ,  510 ,  610 ,  710  and each of the interfaces  103 ,  203 ,  303 ,  403 ,  503 ,  603 ,  703  and  105 ,  205 ,  305 ,  405 ,  505 ,  605 ,  705 ,  805 ″. Method  1300  concludes at block  1310  by cooling the thermoplastic film  310 ,  410 ,  510 ,  610 ,  710  and the interfaces  103 ,  203 ,  303 ,  403 ,  503 ,  603 ,  703  and  105 ,  205 ,  305 ,  405 ,  505 ,  605 ,  705 ,  805 ″ below the melting point of each of the thermoplastic skin  102 ,  202 ,  302 ,  402 ,  502 ,  602 ,  702 , the thermoplastic film  310 ,  410 ,  510 ,  610 ,  710 , and the thermoplastic core  104 ,  204 ,  304 ,  404 ,  504 ,  604 ,  704 ,  804  to consolidate the thermoplastic skin  102 ,  202 ,  302 ,  402 ,  502 ,  602 ,  702 , the thermoplastic film  310 ,  410 ,  510 ,  610 ,  710 , and the thermoplastic core  104 ,  204 ,  304 ,  404 ,  504 ,  604 ,  704 ,  804  into a unitary thermoplastic component  120 ,  220 ,  320 ,  420 ,  520 ,  620 ,  720 . 
     At least one embodiment is disclosed, and variations, combinations, and/or modifications of the embodiment(s) and/or features of the embodiment(s) made by a person having ordinary skill in the art are within the scope of this disclosure. Alternative embodiments that result from combining, integrating, and/or omitting features of the embodiment(s) are also within the scope of this disclosure. Where numerical ranges or limitations are expressly stated, such express ranges or limitations should be understood to include iterative ranges or limitations of like magnitude falling within the expressly stated ranges or limitations (e.g., from about 1 to about 10 includes, 2, 3, 4, etc.; greater than 0.10 includes 0.11, 0.12, 0.13, etc.). For example, whenever a numerical range with a lower limit, R l , and an upper limit, R u , is disclosed, any number falling within the range is specifically disclosed. In particular, the following numbers within the range are specifically disclosed: R=R l +k*(R u −R l ), wherein k is a variable ranging from 1 percent to 100 percent with a 1 percent increment, i.e., k is 1 percent, 2 percent, 3 percent, 4 percent, 5 percent, . . . 50 percent, 51 percent, 52 percent, . . . , 95 percent, 96 percent, 95 percent, 98 percent, 99 percent, or 100 percent. Moreover, any numerical range defined by two R numbers as defined in the above is also specifically disclosed. 
     Use of the term “optionally” with respect to any element of a claim means that the element is required, or alternatively, the element is not required, both alternatives being within the scope of the claim. Use of broader terms such as comprises, includes, and having should be understood to provide support for narrower terms such as consisting of, consisting essentially of, and comprised substantially of. Accordingly, the scope of protection is not limited by the description set out above but is defined by the claims that follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated as further disclosure into the specification and the claims are embodiment(s) of the present invention. Also, the phrases “at least one of A, B, and C” and “A and/or B and/or C” should each be interpreted to include only A, only B, only C, or any combination of A, B, and C.