Method for embedding an elongated base into a thermoplastic body and system for performing the method

Abstract

The present disclosure relates to a method of embedding an elongated base into a thermoplastic body and a system for performing the method. The method includes extending the elongated base in a manner such that an extended portion of the elongated base extends between a guide structure and a body contact structure. The method also includes heating a segment of the elongated base to produce a heated portion of the elongated base. The method also includes pressing a front region of the heated portion of the elongated base through a body surface of the thermoplastic body and into the thermoplastic body. The method also includes operatively translating at least one of a guide structure, a body contact structure, and an applicator tool including the guide structure and the body contact structure along an embedding path of the elongated base.

Description

Technical Field

[0001] The present disclosure generally relates to methods of embedding an elongate susceptor within a thermoplastic body and / or systems for performing the same. Background Art

[0002] Thermoplastic patch panels can be joined to an infrastructure such as an aircraft to assemble the infrastructure and / or repair damaged areas of the infrastructure. Thermoplastic patch panels typically include a thermoplastic body and multiple lengths of an elongated base embedded within the thermoplastic body. The multiple lengths of the elongated base can be inductively heated to at least partially soften and / or melt the thermoplastic body, which can then be applied to the infrastructure. After cooling, the thermoplastic body is joined to the infrastructure, thereby achieving assembly and / or repair.

[0003] In certain applications, it may be desirable to utilize a relatively thin thermoplastic wiring board. In some such examples, the thickness of the thermoplastic body may be similar to or only slightly greater than a characteristic cross-sectional dimension (such as a diameter) of a plurality of lengths of the elongated base. In some such examples, the thermoplastic body may include a large amount of latent stress and / or may deform when heated.

[0004] In the above examples, conventional methods for creating thermoplastic patch panels may be ineffective, may cause unacceptable deformation of the thermoplastic body, and / or may damage the thermoplastic body.Therefore, there is a need for improved methods of embedding an elongated pedestal within a thermoplastic body and / or systems for performing the same. Summary of the invention

[0005] Disclosed herein is a method for embedding an elongated base into a thermoplastic body and a system for performing the method. The method includes extending the elongated base from a guide structure of an application tool to a body contact structure of the application tool, and extending the extended portion of the elongated base between the guide structure and the body contact structure. The method also includes heating a segment of the elongated base to produce a heated portion of the elongated base. The heating includes heating using a heating structure of the application tool and heating to a segment temperature greater than a melting temperature of the thermoplastic body. The method also includes pressing a leading region of the heated portion of the elongated base through a body surface of the thermoplastic body and into the thermoplastic body. The pressing includes pressing using the body contact structure. The method also includes operatively translating at least one of the body contact structure and the application tool along an embedding path of the elongated base, the embedding path being defined along the body surface. The translating is operatively performed simultaneously with the compressing and the extending, and includes smoothing the body surface using the body contact structure.

[0006] The system includes an applicator tool, a translation structure, and a controller. The applicator tool includes a guide structure configured to guide an elongated base, a body contact structure configured to contact a body surface of a thermoplastic body, and a heating structure configured to heat a segment of the elongated base. The translation structure is configured to operatively translate the applicator tool and the thermoplastic body relative to each other along an embedding path of the elongated base. The controller is programmed to control the operation of the applicator tool and the translation structure according to the method. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1 is a schematic diagram of an example of a base structure in the form of an aircraft according to the present disclosure that may be used with a thermoplastic patch panel.

[0008] Figure 2 is a schematic diagram of an example of a thermoplastic repair system that may be used with a thermoplastic patch panel according to the present disclosure.

[0009] Figure 3 yes Figure 2 Another schematic diagram of the thermoplastic repair system.

[0010] Figure 4 is a schematic diagram of an example of a system for embedding a length of an elongated base within a thermoplastic body according to the present disclosure.

[0011] Figure 5is a schematic diagram of an example of a system for embedding a length of an elongated base within a thermoplastic body according to the present disclosure.

[0012] Figure 6 It is along Figure 4 and Figure 5 A schematic cross-sectional view taken along line AA.

[0013] Figure 7 It is along Figure 4 and Figure 5 A schematic cross-sectional view taken along line BB of FIG.

[0014] Figure 8 is a flow chart depicting a method of embedding an elongated susceptor within a thermoplastic body according to the present disclosure. DETAILED DESCRIPTION

[0015] Figures 1 to 8 Illustrative, non-exclusive examples of base structures 80, thermoplastic repair systems 68, systems 10 for embedding a length of an elongated base into a thermoplastic body, and / or methods 200 according to the present disclosure are provided. Figures 1 to 8 The various figures in the drawings are marked with similar numbers and may not be referred to in this article. Figures 1 to 8 These elements are discussed in detail in the various figures in Figures 1 to 8 Not all components may be labeled in the various figures in the present invention, but for consistency, the reference numerals associated therewith may be used herein. Figures 1 to 8 One or more of the elements, components and / or features discussed in the disclosure may be included without departing from the scope of the present disclosure. Figures 1 to 8 Any of and / or with Figures 1 to 8 Use any of them together.

[0016] Typically, elements that may be included in a given (i.e., specific) embodiment are illustrated in solid lines, while elements that are optional for a given embodiment are illustrated in dashed lines. However, elements shown in solid lines are not required for all embodiments, and elements shown in solid lines may be omitted from a specific embodiment without departing from the scope of the present disclosure.

[0017] Figure 1 FIG. 8 is a schematic diagram of an example of a base structure 80 in the form of an aircraft 82 according to the present disclosure that may be used with a thermoplastic wiring panel 90. Figure 1As shown, the aircraft 82 may include one or more thermoplastic distribution panels 90, and the thermoplastic distribution panels 90 may be attached to, engaged with, and / or associated with any suitable component and / or structure of the aircraft 82. In a particular example, the one or more thermoplastic distribution panels 90 may be attached to, engaged with, and / or associated with a fuselage of the aircraft, a wing of the aircraft, an engine of the aircraft, a stabilizer of the aircraft, and / or a tail of the aircraft.

[0018] Figure 2 and Figure 3 is a schematic diagram of an example of a thermoplastic repair system 68 according to the present disclosure that may be used with a thermoplastic wiring panel 90 that may be formed using the described systems and / or methods. Figure 2 and Figure 3 As shown, the thermoplastic repair system 68 includes an induction heating assembly 70, which can be configured to inductively heat the thermoplastic wiring board 90. In a specific example, the induction heating assembly 70 includes an electromagnet 72 and a power source 74. The power source 74 can be configured to provide alternating current or high frequency alternating current to the electromagnet 72. Figure 2 As shown and in response to receiving alternating current, electromagnet 72 may generate and / or produce a magnetic field or high frequency magnetic field 76. Magnetic field 76 may induce current within length 168 of the elongated base embedded in thermoplastic body 40 of thermoplastic patch panel 90, thereby heating the thermoplastic patch panel.

[0019] Then and as Figure 2 The structure shown to Figure 3 As shown in the transition of the configuration shown, the thermoplastic wiring board 90 can be applied to or in contact with the base structure 80. After cooling, the thermoplastic wiring board 90 can be bonded to the base structure 80 and / or can be adhered to the base structure 80. In some examples and as Figure 2 As shown by the dashed lines in FIG. 8 , the base structure 80 may include a damaged region 84. In some such examples and as Figure 3 As shown, a thermoplastic patch panel 90 may be utilized to cover and / or repair the damaged area 84 .

[0020] Figure 4 and Figure 5 is a schematic diagram of an example of a system 10 for embedding a length 168 of an elongated base 154 within a thermoplastic body 40 according to the present disclosure. Figure 4 and Figure 5As shown, the system 10 includes an applicator tool 100, a translation structure 20, and a controller 30. The applicator tool 100 includes a guide structure 110 configured to guide an elongated base 154. The applicator tool 100 also includes a body contact structure 120 configured to contact a body surface 42 of a thermoplastic body 40. The applicator tool 100 also includes a heating structure 130 configured to heat a segment 163 of the elongated base 154, such as to produce and / or generate a heated portion 164 of the elongated base.

[0021] The translation structure 20 is configured to operatively translate the applicator tool 100 and the thermoplastic body 40 relative to each other and / or along the embedding path 60 of the elongated base 154. The controller 30 is adapted, configured, designed and / or programmed to control the operation of at least a portion of the system 10. As an example, the controller 30 may be programmed to control the operation of the applicator tool 100 and / or the translation structure 20. This may include controlling the operation of the portion of the system 10 in accordance with and / or utilizing any suitable steps and / or steps of the method 200 discussed in greater detail herein.

[0022] During operation of the system 10 and as referred to herein Figure 8 The method 200 is described in more detail and in Figure 4 and Figure 5 As illustrated in FIG. 1 , the elongated base 154 can extend from the guide structure 110 and / or to the body contact structure 120 such that an extension portion 156 of the elongated base extends between the guide structure and the body contact structure. Additionally, the heating structure 130 can heat a section 163 of the elongated base 154 to produce and / or generate a heated portion 164 of the elongated base. Both the section 163 and the heated portion 164 can be a subset of the extension portion 156. In other words, the heating structure 130 can be configured to heat at least a subset of the extension portion 156. Additionally, the body contact structure 120 can press a front region 166 of the heated portion 164 through the body surface 42 of the thermoplastic body 40 and into the thermoplastic body.

[0023] The heating portion 164 may be heated to a zone temperature that may be greater than the melting temperature of the thermoplastic body 40. Thus, contact between the heating portion 164 and the thermoplastic body 40 may cause thermal energy to be transferred from the heating portion to the thermoplastic body, thereby melting the melt region 44 of the thermoplastic body.

[0024] Concurrently with the above, the guide structure 110, the body contact structure 120, and / or the applicator tool 100 may be operatively translated relative to the thermoplastic body 40 and / or along the embedding path 60 of the elongated base 154. This process may embed the length 168 of the elongated base 154 within the thermoplastic body 40 and / or along the embedding path 60. In other words, during the operative translation of the guide structure 110, the body contact structure 120, and / or the applicator tool 100 relative to the thermoplastic body 40, the elongated base 154 may be continuously extended from the guide structure 110 and / or to the body contact structure 120 and heated by the heating structure 130, thereby embedding the length 168 of the elongated base within the thermoplastic body 40 along the embedding path 60.

[0025] like Figure 6 ( Figure 6 It is along Figure 4 and Figure 5 As shown in the schematic cross-sectional view taken along line AA of FIG. 1 , the action of pressing the elongated base 154 through the body surface 42 and / or into the thermoplastic body 40 may produce and / or generate a displaced volume 50 of the thermoplastic material 48. The displaced volume 50 may cause unacceptable roughness and / or undulations in the body surface 42 of the thermoplastic body 40. With this in mind and as shown from Figure 6 The structure shown is as follows Figure 7 ( Figure 7 It is along Figure 4 and Figure 5 As shown in the schematic cross-sectional view taken along line BB of FIG, the body contact structure 120 can smooth the body surface 42 when the body contact structure is operatively translated across the body surface.

[0026] More generally back Figure 4 and Figure 5 , the guide structure 110 may include any suitable structure that may be adapted, configured, designed and / or constructed to guide and / or direct the elongated base 154, such as to the body contact structure 120 and / or to guide and / or direct the elongated base 154 along the embedding path 60. This may include precisely directing the elongated base 154 toward and / or into contact with the body surface 42, which may allow and / or facilitate precise placement of the length 168 of the elongated base within the thermoplastic body 40. Examples of the guide structure 110 include the tube 112 and / or the channel 114.

[0027] The body contact structure 120 may include any suitable structure that may be adapted, configured, designed, and / or constructed to contact the body surface 42 to press the elongated base 154 through the body surface 42 and into the thermoplastic body 40 and / or smooth the body surface 42. This may include accurately guiding the elongated base 154 through the body surface 42, which may allow and / or facilitate accurate placement of the length 168 of the elongated base 154 within the thermoplastic body 40. Examples of the body contact structure 120 include a body contact surface, a smooth surface, an arcuate surface, and / or a roller. In some examples, the body contact structure 120 may include a groove 126 that may be configured to accommodate and / or guide the elongated base 154. In some such examples, the body contact structure 120 may include and / or be a grooved body contact surface, a grooved smooth surface, a grooved arcuate surface, and / or a grooved roller.

[0028] In some examples of the applicator tool 100 and as Figure 4 As shown, the body contact structure 120 may include and / or may be a single body contact structure 120. The single body contact structure 120 may be configured to receive the extension portion 156 of the elongated base 154 extending from the guide structure 110 to press the front region 166 through the body surface 42 and also smooth the body surface 42.

[0029] In some examples of the applicator tool 100 and as Figure 5 As shown, the body contact structure 120 may include a front body contact structure 122 and a rear body contact structure 124 that may be spaced apart from the front body contact structure. In some such examples, the guide structure 110 may include and / or may be a front body contact structure.

[0030] In some such examples, the guide structure 110 can be separate, distinct, and / or spaced apart from the front body contact structure 122. In these examples, a front region 160 of the extension 156 of the elongated base 154 can extend between the guide structure 110 and the front body contact structure 122, and a rear region 162 of the extension 156 of the elongated base 154 can extend between the front body contact structure 122 and the rear body contact structure 124. In these examples, the front body contact structure 122 can press the elongated base 154 through the body surface 42 and / or into the thermoplastic body 40, and the rear body contact structure 124 can smooth the body surface 42.

[0031] The heating structure 130 may include any suitable structure that may be adapted, configured, designed, and / or constructed to heat the segment 163 of the elongated base 154 and / or produce and / or generate a heated portion 164 of the elongated base 154. In some examples, the heating structure 130 may be configured to electrically heat the segment 163 of the elongated base 154. As an example, the heating structure 130 may include a power source 132 configured to provide an electric current 134 to the segment 163 of the elongated base 154, such as to resistively heat the segment 163 of the elongated base. In some such examples, the electric current 134 may flow within the elongated base 154 between the guide structure 110 and the body contact structure 120, between the guide structure 110 and the front body contact structure 122, and / or between the front body contact structure 122 and the rear body contact structure 124.

[0032] In some examples, the heating structure 130 can be configured to inductively heat the section 163 of the elongated base 154. As an example, the heating structure 130 can include an electromagnet 136 and a high-frequency AC power source 140. In such an example, the high-frequency AC power source 140 can be configured to provide a high-frequency AC current to the electromagnet 136, and in response to receiving the high-frequency AC current, the electromagnet 136 can generate and / or produce a high-frequency electromagnetic field 138. The high-frequency electromagnetic field can induce an electric current in the section 163 of the elongated base 154, thereby heating the section of the elongated base.

[0033] like Figure 4 and Figure 5 As shown in dashed lines in FIG, the applicator tool 100 may include and / or may be associated with an elongated base source 150. The elongated base source 150, if present, may be configured to provide an elongated base 154 to the guide structure 110. Examples of the elongated base source 150 include a spool 152 of elongated base material.

[0034] The translation structure 20 may include any suitable structure that may be adapted, configured, designed and / or constructed to operatively translate, move and / or rotate the applicator tool 100 and the thermoplastic body 40 relative to each other. This may include operatively translating, moving and / or rotating the applicator tool 100 relative to the thermoplastic body 40 and / or operatively translating, moving and / or rotating the thermoplastic body 40 relative to the applicator tool 100. Examples of the translation structure 20 include a motor, an electric motor, a stepper motor, a gear assembly, a linear actuator, a rotary actuator, a translation stage, a two-dimensional translation stage and / or a three-dimensional translation stage.

[0035] The controller 30 may include any suitable structure that may be adapted, configured, designed, and / or programmed to control the operation of at least one other component of the system 10, such as the applicator tool 100 and / or the translation structure 20. This may include controlling the at least one other component of the system 10 according to any suitable steps and / or steps of the method 200 discussed in greater detail herein. Examples of the controller 30 include an electronic controller, a dedicated controller, a special purpose controller, a personal computer, a special purpose computer, a display device, a logic device, a storage device, and / or a storage device having a computer-readable storage medium.

[0036] The computer-readable storage medium, if present, may also be referred to herein as a non-transitory computer-readable storage medium. The non-transitory computer-readable storage medium may include, define, contain and / or store computer-executable instructions, programs and / or codes; and these computer-executable instructions may direct the system 10 to perform any suitable portion or subset of the method 200. Examples of such non-transitory computer-readable storage media include CD-ROMs, disks, hard drives, flash memories, etc. As used herein, storage or memory, devices and / or media having computer-executable instructions, and computer-implemented methods and other methods according to the present disclosure are considered within the scope of subject matter considered patentable under 35 U.S.C. § 101.

[0037] Thermoplastic body 40 may include any suitable structure and / or material that may accommodate length 168 of elongated base 154 and / or may be used in thermoplastic patch panel 90. Examples of thermoplastic body 40 include a sheet of thermoplastic material 48. Thermoplastic body 40 may include and / or may be defined by any suitable thermoplastic material 48, examples of which include polymeric materials and / or polyetheretherketone.

[0038] In some examples, the thermoplastic body 40 can be relatively thin, as measured in a direction perpendicular to the body surface 42. For example and as Figure 6 to Figure 7 As shown, the thickness 52 of the thermoplastic body 40 can be at least 0.01 millimeters (mm), at least 0.02 mm, at least 0.03 mm, at least 0.04 mm, at least 0.05 mm, at least 0.075 mm, at least 0.1 mm, at least 0.2 mm, at least 0.3 mm, at least 0.4 mm, at least 0.5 mm, at most 2.5 mm, at most 2 mm, at most 1.5 mm, at most 1 mm, at most 0.9 mm, at most 0.8 mm, at most 0.7 mm, at most 0.6 mm, at most 0.5 mm, at most 0.4 mm, at most 0.3 mm, at most 0.2 mm, at most 0.1 mm and / or at most 0.05 mm.

[0039] In some examples, thickness 52 may be less than a threshold multiple of a maximum base cross-sectional dimension 158, such as a diameter of elongated base 154. Examples of threshold multiples include multiples of 10, 8, 6, 5, 4, 3, 2, 1.5, or 1.

[0040] The elongated base 154 may include any suitable structure and / or material that can extend between the guide structure 110 and the body contact structure 120, can be heated by the heating structure 130, and / or can be pressed through the body surface 42 by the body contact structure 120. In some examples, the elongated base 154 may include and / or may be defined by a base material configured to absorb high-frequency magnetic fields and thereby generate heat. In some examples, the elongated base 154 may include and / or may be a conductive material, a metal, and / or a ferromagnetic material. In some examples, the elongated base 154 may include and / or may be an elongated wire. In some such examples, the elongated wire may include an electrical insulator that may coat the outer surface of the elongated wire. Examples of electrical insulators include dielectric materials and / or polymers.

[0041] Figure 8 is a flow chart depicting a method 200 of embedding an elongated base within a thermoplastic body according to the present disclosure. The method 200 includes extending the elongated base at 210 and heating a section of the elongated base at 220. The method 200 also includes pressing a front region of the heated portion of the elongated base at 230 and operatively translating along an embedding path at 240. The method 200 may also include cooling the melted region at 250 and / or repeating at least a subset of the method at 260.

[0042] Extending the elongated base at 210 may include extending the elongated base from a guide structure of the applicator tool and / or to a body contact structure of the applicator tool. This may include extending the elongated base in a manner such that an extended portion of the elongated base extends between the guide structure and the body contact structure. In some examples, extending at 210 may include extending from an elongated base source. Figure 4 and Figure 5 An example of an elongated pedestal source is disclosed. Figures 4 to 7 An example of an elongated base is disclosed in the elongated base 154. Figure 4 and Figure 5 An example of a guide structure is disclosed in the guide structure 110 .

[0043] In some examples and during or at least during the operative translation at 240, the extending at 210 may include continuously moving the extended portion of the elongated base along its elongated axis. In other words, the continuously moving may include continuously moving the extended portion of the elongated base relative to the application tool. In yet other words, the extending at 210 may include transferring a given area of ​​the elongated base from the guide structure and to the body contact structure before the given area of ​​the elongated base is embedded in the thermoplastic body (such as during the pressing at 230).

[0044] In some examples, the body contact structure may include a rear body contact structure and a front body contact structure spaced apart from the rear body contact structure. Figure 5 Examples of rear body contact structures and front body contact structures are disclosed in the rear body contact structure 124 and the front body contact structure 122. In some such examples, the guide structure includes a front body contact structure.

[0045] In such examples, the front body contact structure can be different from and / or spaced apart from the guide structure. In such examples, the extension at 210 can include extending a front region of the extension portion of the elongated base from the guide structure to the front body contact structure. In such examples, the extension at 210 can additionally or alternatively include extending a rear region of the extension portion of the elongated base from the front body contact structure to the rear body contact structure. In some such examples, the pressing at 230 can include pressing with the front body contact structure. In some such examples, the operative translation at 240 can include smoothing the body surface with the rear body contact structure.

[0046] The extension of the elongated base can have and / or define an extension length, such as can be measured between the guide structure and the body contact structure, between the guide structure and the front body contact structure, between the guide structure and the rear body contact structure, and / or between the front body contact structure and the rear body contact structure. Examples of extension lengths include lengths of at least 0.5 mm, at least 1 mm, at least 2 mm, at least 3 mm, at least 4 mm, at least 5 mm, at least 6 mm, at least 7 mm, at least 8 mm, at least 9 mm, at least 10 mm, at most 25 mm, at most 20 mm, at most 18 mm, at most 16 mm, at most 14 mm, at most 12 mm, at most 10 mm, at most 8 mm, and / or at most 6 mm. In some examples, the extension can have and / or define an aspect ratio, which can be defined as the ratio of the extension length to a characteristic cross-sectional dimension (such as a diameter and / or a characteristic diameter) of the elongated base. Examples of aspect ratios include aspect ratios of at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at most 100, at most 90, at most 80, at most 70, at most 60, at most 50, at most 40, at most 30, at most 20, and / or at most 10.

[0047] The extension at 210 may be performed at any suitable timing and / or sequence during method 200. As an example, the extension at 210 may be performed at least partially simultaneously with and / or during the heating at 220, the pressing at 230, the operational translation at 240, and / or the cooling at 250.

[0048] Heating the segment of the elongated base at 220 may include heating the segment of the elongated base to a segment temperature that may be greater than the melting temperature of the thermoplastic body. Additionally or alternatively, the heating at 220 may include heating the segment of the elongated base to produce and / or generate a heated portion of the elongated base. The heated portion of the elongated base may include and / or may be a subset of the extended portion of the elongated base. In other words, the heating at 220 may include heating a region of the extended portion of the elongated base.

[0049] The heating at 220 may be accomplished in any suitable manner. As an example, the heating at 220 may include heating by, via, and / or utilizing a heating structure such as Figure 4 and Figure 5 In some such examples, the heating structure may be spaced apart and / or different from the main body contact structure.

[0050] In some examples and as discussed, the elongated base can include an electrical insulator coating an outer surface of the elongated base. In such examples, the heating at 220 can include heating without melting the electrical insulator.

[0051] The heating at 220 may be performed at any suitable timing and / or sequence during method 200. As an example, the heating at 220 may be performed at least partially simultaneously with and / or during the extending at 210, the pressing at 230, the operationally translating at 240, and / or the cooling at 250.

[0052] In some examples, the heating at 220 may include electrically heating a segment of the elongated base. In some such examples, the electrical heating may include providing an electric current to the segment of the elongated base, such as resistively heating the segment of the elongated base. In some such examples, the heating structure may include a power source that may be configured to provide an electric current to the segment of the elongated base. In some such examples, the heating at 220 may include causing an electric current to flow through the segment of the elongated base, between the guide structure and the body contact structure, and / or between the front body contact structure and the rear body contact structure.

[0053] In some examples, the heating at 220 may include inductively heating the segment of the elongated base. In some such examples, the inductive heating may include applying a high-frequency electromagnetic field to the segment of the elongated base. In some such examples, the heating assembly may include an electromagnet and a high-frequency AC power source. In some such examples, the heating at 220 may include applying a high-frequency current to the electromagnet using the high-frequency AC power source, and generating a high-frequency electromagnetic field using the electromagnet in response to receiving the high-frequency current.

[0054] In some examples, the heating at 220 can include heating the segment of the elongated base from an ambient temperature and / or to a segment temperature in less than a threshold heating time. Examples of threshold heating times include threshold heating times of at least 0.01 seconds (s), at least 0.05 s, at least 0.1 s, at least 0.2 s, at least 0.3 s, at least 0.4 s, at least 0.5 s, at least 0.6 s, at least 0.7 s, at least 0.8 s, at least 0.9 s, at least 1 s, at most 5 s, at most 4 s, at most 3 s, at most 2 s, at most 1.5 s, at most 1 s, at most 0.8 s, and / or at most 0.6 s. Such relatively rapid heating of the segment of the elongated base can reduce the likelihood of unwanted and / or undesirable heating of the rest of the application tool and / or the thermoplastic body, which can reduce the likelihood of deformation of the thermoplastic body.

[0055] Pressing the front region of the heating portion of the elongated base at 230 may include pressing the front region through the body surface of the thermoplastic body and / or into the thermoplastic body. Pressing at 230 may include at least partially or even completely embedding the front region within the thermoplastic body. Additionally or alternatively, pressing at 230 may include at least partially or even completely encapsulating the front region within the thermoplastic body.

[0056] The pressing at 230 may be accomplished in any suitable manner. As an example, the pressing at 230 may include pressing through, via, and / or with the body contact structure and / or the front body contact structure (if present).

[0057] In some examples, pressing at 230 can include melting the melt region of the thermoplastic body, such as via heat transfer from a heated portion of the elongated base and / or into the thermoplastic body. Figures 4 to 7 An example of a melting region is disclosed by the melting region 44. In some examples, the melting region can be relatively small and / or at least one dimension of the melting region can be comparable to a corresponding dimension of the elongated base.

[0058] As an example, the melt region may have and / or define a maximum melt region cross-sectional extent that may be measured perpendicular to the elongated axis of the melt region. Examples of maximum melt region cross-sectional extents are Figure 6 to Figure 7 exemplified in and indicated at 46. Similarly, the front region of the heated portion of the elongated susceptor may define a maximum susceptor cross-sectional dimension that may be measured perpendicular to the melting region and / or the elongated axis of the elongated susceptor. Examples of maximum susceptor cross-sectional dimensions are shown in Figure 6 to Figure 7 exemplified in and indicated at 158. In such examples, melting may include melting in such a manner that a ratio of a maximum melt region cross-sectional extent to a maximum base cross-sectional extent may be at least 1.1, at least 1.25, at least 1.5, at least 1.75, at least 2, at most 5, at most 4, at most 3, at most 2.5, at most 2, and / or at most 1.5. In other words, pressing at 230 may cause only localized melting of the thermoplastic body, which may reduce the likelihood of damaging and / or deforming the thermoplastic body. Additionally or alternatively, localized melting may allow the elongated base to be embedded within the thermoplastic body even when the thickness of the thermoplastic body is less than a threshold multiple of the maximum base cross-sectional dimension. Examples of threshold multiples are disclosed herein.

[0059] The pressing at 230 may be performed at any suitable timing and / or sequence during method 200. As an example, the pressing at 230 may be performed at least partially simultaneously with and / or during the extending at 210, the heating at 220, the operationally translating at 240, and / or the cooling at 250.

[0060] Operationally translating along the embedding path at 240 may include operatively translating a guide structure, a body contact structure, and / or an applicator tool along the embedding path of the elongated base. The embedding path may be defined along a body surface of the thermoplastic body and / or a desired position of the elongated base or an embedding length of the elongated base within the thermoplastic body may be defined. Figure 4 and Figure 5 An example of an embedding path is disclosed in 240. Operationally translating may include translating through, via, and / or utilizing a translation structure (referenced herein). Figure 4 and Figure 5 The translation structure 20 of the present invention discloses an example of a translation structure) to translate in operation, and the translation structure can be implemented in any suitable manner. As an example, the translation in operation at 240 can include moving the application tool relative to the thermoplastic body, and / or moving the thermoplastic body relative to the application tool.

[0061] Additionally or alternatively, operatively translating at 240 may include smoothing the body surface, such as with a body contact structure. Figure 6 As exemplified in and herein referred to Figure 6 As discussed in more detail, pressing at 230 may include displacing a displacement volume of thermoplastic material, such as displacement volume 50, in a manner such that the displacement volume of thermoplastic material extends from and / or over a body surface of the thermoplastic body. In such examples, smoothing may include at least partially flattening the displacement volume of thermoplastic material, at least partially flattening the body surface of the thermoplastic body, and / or pressing the displacement volume of thermoplastic material toward the body surface of the thermoplastic body, such as Figure 6 The structure shown to Figure 7 The construction shown is exemplified.

[0062] The operational translation at 240 may be performed at any suitable timing and / or sequence during method 200. As an example, the operational translation at 240 may be performed at least partially simultaneously with and / or during the extension at 210, the heating at 220, the pressing at 230, and / or the cooling at 250.

[0063] Cooling the molten region at 250 may include cooling the molten region to solidify the molten region and / or to maintain the embedded length of the elongated base within the thermoplastic body. The cooling at 250 may be accomplished in any suitable manner, such as via natural convection, forced convection, and / or conduction of thermal energy from the molten region to an ambient environment surrounding the thermoplastic body and / or into the thermoplastic body.

[0064] The cooling at 250 may be performed at any suitable timing and / or sequence during the method 200. As an example, the cooling at 250 may be performed at least partially simultaneously with and / or during the extending at 210, the heating at 220, the pressing at 230, and / or the operatively translating at 240. Additionally or alternatively, for a given melt region of the thermoplastic body, the cooling at 250 may be performed after the pressing at 230 and / or after the smoothing.

[0065] Repeating at least a subset of the method at 260 may include repeating any suitable steps and / or steps of method 200 in any suitable order. As an example, the repeating at 260 may include multiple repetitions of the extending at 210, the heating at 220, the pressing at 230, the operatively translating at 240, and / or the cooling at 250, such as to embed multiple lengths of the elongated base in and / or within the thermoplastic material. In some such examples, the repeating at 260 may also include severing the elongated base to embed multiple discrete, separate, and / or spaced-apart lengths of the elongated base in and / or within the thermoplastic material.

[0066] As discussed in more detail herein, in situations that may be challenging for conventional processes, systems and methods according to the present disclosure may allow and / or facilitate embedding an elongated pedestal within a thermoplastic body and / or forming a thermoplastic wiring board. As an example, the systems and methods disclosed herein may allow and / or facilitate the precise placement and / or positioning of multiple lengths of an elongated pedestal within a given thermoplastic body to form and / or define a thermoplastic wiring board having desired inductive heating characteristics. This may include embedding multiple lengths of an elongated pedestal at varying intervals and / or varying pedestal lengths. Additionally or alternatively, the systems and methods disclosed herein may allow and / or facilitate performing the extension at 210, the heating at 220, the pressing at 230, the operational translation at 240, and / or the cooling at 250 without distorting and / or deforming the thermoplastic body.

[0067] Illustrative, non-exclusive examples of inventive subject matter according to the present disclosure are described in the following enumerated paragraphs:

[0068] A1. A method of embedding an elongated base into a thermoplastic body, the method comprising the steps of:

[0069] extending the elongated base, the elongated base optionally extending from a guide structure of an applicator instrument to a body contact structure of the applicator instrument such that an extended portion of the elongated base extends between the guide structure and the body contact structure;

[0070] optionally heating a segment of the elongated base to a segment temperature greater than a melting temperature of the thermoplastic body using a heating structure of the applicator tool to produce a heated portion of the elongated base, optionally wherein the heated portion is a subset of the extended portion of the elongated base;

[0071] optionally using the body contact structure, pressing a front region of the heating portion of the elongated base through a body surface of the thermoplastic body and into the thermoplastic body; and

[0072] Simultaneously with said pressing and said extending, at least one of said guide structure, said body contact structure and said applicator tool is operatively translated along an embedding path of said elongated base, optionally wherein said embedding path is defined along said body surface, and further optionally wherein said operative translation comprises optionally smoothing said body surface using said body contact structure.

[0073] A2. The method of paragraph A1, wherein the extending comprises extending from an elongated base source.

[0074] A3. A method according to paragraph A2, wherein the slender base source includes a spool of slender base material.

[0075] A4. A method according to any of paragraphs A1 to A3, wherein the extending includes continuously moving the extended portion of the slender base along the slender axis of the slender base at least during the operative translation.

[0076] A5. The method of paragraph A4, wherein the continuously moving comprises continuously moving the extension portion of the elongated base relative to the applicator tool.

[0077] A6. The method of any of paragraphs A1 to A5, wherein the guide structure comprises at least one of a tube and a channel.

[0078] A7. A method according to any of paragraphs A1 to A6, wherein the guide structure is configured to precisely position the slender base relative to the body contact structure.

[0079] A8. The method of any of paragraphs A1 to A7, wherein the body contact structure includes a rear body contact structure and a front body contact structure spaced apart from the rear body contact structure.

[0080] A9. A method according to paragraph A8, wherein the guide structure includes the front body contact structure.

[0081] A10. A method according to paragraph A8 or A9, wherein the front body contact structure is different from the guide structure, and further, wherein the extension includes extending a front region of the extension portion of the slender base from the guide structure to the front body contact structure, and extending a rear region of the extension portion of the slender base from the front body contact structure to the rear body contact structure.

[0082] A11. The method of paragraph A10, wherein the pressing comprises pressing using the front body contact structure.

[0083] A12. The method of paragraph A10 or A11, wherein the smoothing comprises smoothing using the rear body contact structure.

[0084] A13. The method of any of paragraphs A1 to A12, wherein the extension portion of the elongated base defines an extension portion length.

[0085] A14. The method of paragraph A13, wherein the extending comprises extending in a manner such that the length of the extended portion is at least one of:

[0086] (i) at least 0.5 millimeters (mm), at least 1 mm, at least 2 mm, at least 3 mm, at least 4 mm, at least 5 mm, at least 6 mm, at least 7 mm, at least 8 mm, at least 9 mm, or at least 10 mm; and

[0087] (ii) up to 25 mm, up to 20 mm, up to 18 mm, up to 16 mm, up to 14 mm, up to 12 mm, up to 10 mm, up to 8 mm or up to 6 mm.

[0088] A15. The method of paragraph A13 or A14, wherein the extending comprises extending in a manner such that an aspect ratio of the extended portion is at least one of:

[0089] (i) at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, or at least 50; and

[0090] (ii) up to 100, up to 90, up to 80, up to 70, up to 60, up to 50, up to 40, up to 30, up to 20 or up to 10.

[0091] A16. A method according to any of paragraphs A1 to A15, wherein the heating includes electrically heating the section of the slender base.

[0092] A17. A method according to paragraph A16, wherein the heating includes providing an electric current to the segment of the slender base to resistively heat the segment of the slender base.

[0093] A18. The method of paragraph A16 or A17, wherein the heating structure includes a power source.

[0094] A19. The method of any of paragraphs A16 to A18, wherein the heating comprises passing an electric current through the segment of the elongated base, optionally in at least one of the following:

[0095] (i) between the guide structure and the body contact structure; and

[0096] (ii) Between the front body contact structure and the rear body contact structure.

[0097] A20. A method according to any of paragraphs A1 to A19, wherein the heating includes inductively heating the section of the slender base.

[0098] A21. A method according to paragraph A20, wherein the heating includes applying a high-frequency electromagnetic field to the section of the slender base.

[0099] A22. A method according to paragraph A20 or A21, wherein the heating component includes an electromagnet and a high-frequency AC power supply, wherein the method includes the following steps: using the high-frequency AC power supply to provide a high-frequency current to the electromagnet, and further, wherein the method includes the following steps: using the electromagnet to generate a high-frequency electromagnetic field in response to receiving the high-frequency current.

[0100] A23. A method according to any of paragraphs A20 to A22, wherein the heating assembly is spaced apart from the body contact structure.

[0101] A24. A method according to any of paragraphs A21 to A23, wherein the heating includes heating the segment of the slender base from an ambient temperature to the segment temperature in less than a threshold heating time.

[0102] A25. The method of any of paragraphs A21 to A24, wherein the threshold heating time is at least one of:

[0103] (i) at least 0.01 seconds (s), at least 0.05 seconds, at least 0.1 seconds, at least 0.2 seconds, at least 0.3 seconds, at least 0.4 seconds, at least 0.5 seconds, at least 0.6 seconds, at least 0.7 seconds, at least 0.8 seconds, at least 0.9 seconds or at least 1 second; and

[0104] (ii) up to 5 seconds, up to 4 seconds, up to 3 seconds, up to 2 seconds, up to 1.5 seconds, up to 1 second, up to 0.8 seconds or up to 0.6 seconds.

[0105] A26. A method according to any of paragraphs A21 to A25, wherein the pressing includes at least partially or even completely embedding the front region of the heating portion of the slender base into the thermoplastic body.

[0106] A27. A method according to any of paragraphs A21 to A26, wherein the pressing includes encapsulating the front region of the heating portion of the slender base within the thermoplastic body.

[0107] A28. The method of any of paragraphs A21 to A27, wherein the pressing includes melting a melt region of the thermoplastic body via heat transfer from the heated portion of the elongated base.

[0108] A29. The method of paragraph A28, wherein, after the smoothing, the method further comprises the step of cooling the molten region to solidify the molten region and maintain the embedded length of the elongated base within the thermoplastic body.

[0109] A30. A method according to paragraph A28 or A29, wherein the melting region defines a maximum melting region cross-sectional extent measured perpendicular to the elongated axis of the melting region, wherein the front region of the heated portion of the elongated pedestal defines a maximum pedestal cross-sectional dimension measured perpendicular to the elongated axis of the melting region, and further, wherein the melting includes melting in a manner such that a ratio of the maximum melting region cross-sectional extent to the maximum pedestal cross-sectional dimension is at least one of the following:

[0110] (i) at least 1.1, at least 1.25, at least 1.5, at least 1.75, or at least 2; and

[0111] (ii) up to 5, up to 4, up to 3, up to 2.5, up to 2 or up to 1.5.

[0112] A31. The method of any of paragraphs A1 to A30, wherein operatively translating comprises at least one of:

[0113] (i) moving the applicator tool relative to the thermoplastic body; and

[0114] (ii) moving the thermoplastic body relative to the applicator tool.

[0115] A32. A method according to any of paragraphs A1 to A31, wherein the pressing includes displacing a displacement volume of thermoplastic material defining the thermoplastic body in a manner such that the displacement volume of the thermoplastic material extends from the body surface of the thermoplastic body.

[0116] A33. The method of paragraph A32, wherein the smoothing comprises at least one of the following:

[0117] (i) at least partially flattening the displaced volume of thermoplastic material;

[0118] (ii) at least partially planarizing the body surface of the thermoplastic body; and

[0119] (iii) pressing the displaced volume of thermoplastic material towards the body surface of the thermoplastic body.

[0120] A34. A method according to any of paragraphs A1 to A33, wherein the slender base includes a base material, which is configured to absorb high-frequency electromagnetic fields and thereby generate heat.

[0121] A35. A method according to any of paragraphs A1 to A34, wherein the slender base includes at least one of a conductive material, a metal, and a ferromagnetic material.

[0122] A36. A method according to any of paragraphs A1 to A35, wherein the slender base includes a slender wire.

[0123] A37. A method according to any of paragraphs A1 to A36, wherein the slender base includes an electrical insulator coating an outer surface of the slender base.

[0124] A38. A method according to paragraph A37, wherein the method includes the following steps: performing the heating without melting the electrical insulator.

[0125] A39. A method according to any of paragraphs A1 to A38, wherein the method includes the following steps: performing at least the stretching, the heating, the pressing, the operatively translating, and the smoothing without distorting the thermoplastic body.

[0126] A40. The method of any of paragraphs A1 to A39, wherein the thermoplastic body is a sheet of thermoplastic material.

[0127] A41. The method of any of paragraphs A1 to A40, wherein the thickness of the thermoplastic body measured between the body surface and the opposite body surface is at least one of the following:

[0128] (i) at least 0.01 mm, at least 0.02 mm, at least 0.03 mm, at least 0.04 mm, at least 0.05 mm, at least 0.075 mm, at least 0.1 mm, at least 0.2 mm, at least 0.3 mm, at least 0.4 mm, or at least 0.5 mm; and

[0129] (ii) up to 2.5 mm, up to 2 mm, up to 1.5 mm, up to 1 mm, up to 0.9 mm, up to 0.8 mm, up to 0.7 mm, up to 0.6 mm, up to 0.5 mm, up to 0.4 mm, up to 0.3 mm, up to 0.2 mm, up to 0.1 mm or up to 0.05 mm.

[0130] A42. A method as described in any of paragraphs A1 to A41, wherein the thickness of the thermoplastic body is less than a threshold multiple of the maximum base cross-sectional dimension of the slender base.

[0131] A43. A method according to paragraph A42, wherein the threshold multiple is 10 times, 8 times, 6 times, 5 times, 4 times, 3 times, 2 times, 1.5 times or 1 times.

[0132] A44. The method of any of paragraphs A1 to A43, wherein the thermoplastic body is defined by at least one of a thermoplastic material, a polymer material, and polyetheretherketone.

[0133] A45. A method according to any one of paragraphs A1 to A44, wherein the method further includes the following steps: repeating the extending, the heating, the pressing and the operatively translating at least multiple times to embed multiple lengths of the slender base into the thermoplastic material.

[0134] B1. A system for embedding a length of an elongated base into a thermoplastic body, the system comprising:

[0135] An application tool, the application tool comprising:

[0136] (i) a guide structure configured to guide the elongated base;

[0137] (ii) a body contact structure configured to contact a main body of the thermoplastic body;

[0138] body surface; and

[0139] (iii) a heating structure configured to heat a section of the elongated base;

[0140] a translation structure configured to operatively translate the applicator tool and the thermoplastic body relative to each other along an embedding path of the elongated base; and

[0141] A controller programmed to control operation of the applicator tool and the translation structure according to the method described in any of Paragraphs A1 to A45.

[0142] As used herein, the terms "selective" and "selectively" when modifying the action, movement, configuration, or other activity of one or more components or characteristics of a device, mean that the particular action, movement, configuration, or other activity is the direct or indirect result of a user manipulating one aspect or one or more components of the device.

[0143] As used herein, the terms "adaptation" and "configuration" refer to that an element, component or other subject is designed and / or intended to perform a given function. Therefore, the use of the terms "adaptation" and "configuration" should not be interpreted as meaning that a given element, component or other subject is only "able to" perform a given function, but that the element, component and / or other subject is specifically selected, created, implemented, utilized, programmed and / or designed for the purpose of performing the function. Within the scope of the present disclosure, the subject of the elements, components and / or other records that are recorded as being adapted to perform a specific function can be described additionally or alternatively as being constructed to perform the function, and vice versa. Similarly, the subject that is recorded as being constructed to perform a specific function can be described alternatively or additionally as being operable to perform the function.

[0144] As used herein, in the context of referring to a list of one or more entities, the phrase "at least one" should be understood to refer to at least one entity selected from any one or more entities in the entity list, but does not necessarily include at least one entity of each entity explicitly listed in the entity list, and does not exclude any combination of entities in the entity list. This limitation also allows that in addition to the entities specifically identified in the entity list referred to by the phrase "at least one", entities may optionally be present, whether related or unrelated to those specifically identified entities. 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 that optionally includes more than one A but not B (and optionally includes entities other than B); in another embodiment, may refer to at least one that optionally includes more than one B but not A (and optionally includes entities other than A); in yet another embodiment, may refer to at least one that optionally includes more than one A and at least one that optionally includes more than one B (and optionally includes other entities). In other words, the phrases "at least one," "one or more," and "and / or" are open-ended expressions that are both conjunctive and disjunctive 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" may refer to A alone, B alone, C alone, A and B together, A and C together, B and C together, A, B, and C together, and optionally any of the foregoing in combination with at least one other entity.

[0145] Not all devices and methods according to the present disclosure require the various disclosed elements and method steps of the device disclosed herein, 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 can define an independent inventive subject matter, which is separated or different from the entirety of the disclosed device or method. Therefore, it is not necessary to associate such an inventive subject matter with the specific device and method clearly disclosed herein, and such an inventive subject matter can be used in devices and / or methods not clearly disclosed herein.

[0146] As used herein, the phrase "for example," the phrase "as an example," and / or simply the term "example," when used with reference to one or more components, features, details, structures, implementations, and / or methods according to the present disclosure, is intended to convey that the described components, features, details, structures, implementations, and / or methods are illustrative, non-exclusive examples of components, features, details, structures, implementations, and / or methods according to the present disclosure. Thus, the described components, features, details, structures, implementations, and / or methods are not intended to be limiting, requiring, or exclusive / exhaustive; other components, features, details, structures, implementations, and / or methods, including components, features, details, structures, implementations, and / or methods that are structurally and / or functionally similar and / or equivalent, are also within the scope of the present disclosure.

[0147] As used herein, "at least substantially" when modifying a degree or relationship may include not only the "substantially" described degree or relationship, but also the full range of the described degree or relationship. A substantial amount of a described degree or relationship may include at least 75% of the described degree or relationship. For example, an object at least substantially formed of a material includes an object in which at least 75% of the object is formed of the material, and also includes an object formed entirely of the material. As another example, a first length that is at least substantially the same length as a second length includes a first length that is within 75% of the second length, and also includes a first length that is the same length as the second length.

Claims

1. A method (200) of embedding an elongated base (154) into a thermoplastic body (40), the method (200) comprising the steps of: extending (210) the elongated base (154) from the guide structure (110) to the body contact structure (120) of the applicator tool (100) in such a manner that the extension portion (156) of the elongated base (154) extends between the guide structure (110) of the applicator tool (100) and the body contact structure (120) of the applicator tool (100); heating (220) a segment (163) of the elongated base (154) to a segment temperature greater than a melting temperature of the thermoplastic body (40) using a heating structure (130) of the applicator tool (100) to produce a heated portion (164) of the elongated base (154); using the body contact structure (120), pressing (230) a front region (166) of the heating portion (164) of the elongated base (154) through a body surface (42) of the thermoplastic body (40) and into the thermoplastic body (40); and Concurrently with said compressing (230) and said extending (210), at least one of said body contact structure (120) and said applicator tool (100) is operatively translated (240) along an embedding path (60) of said elongated base (154), wherein said embedding path (60) is defined along said body surface (42), and further wherein said operatively translating (240) comprises smoothing said body surface (42) with said body contact structure (120), wherein the body contact structure (120) comprises a rear body contact structure (124) and a front body contact structure (122) spaced apart from the rear body contact structure (124), wherein the pressing (230) comprises pressing with the front body contact structure (122), and further wherein the smoothing comprises smoothing with the rear body contact structure (124), wherein the pressing (230) comprises displacing a displacement volume (50) of a thermoplastic material (48) defining the thermoplastic body (40) in a manner such that the displacement volume (50) of the thermoplastic material (48) extends from the body surface (42) of the thermoplastic body (40), and further wherein the smoothing comprises at least one of: (i) at least partially flattening the displaced volume (50) of the thermoplastic material (48); (ii) at least partially planarizing the body surface (42) of the thermoplastic body (40); and (iii) pressing the displaced volume (50) of the thermoplastic material (48) toward the body surface (42) of the thermoplastic body (40).

2. The method (200) according to claim 1, wherein: The heating (220) includes inductively heating the section (163) of the elongated base (154).

3. The method (200) according to claim 1 or 2, wherein: The extension (210) includes extending from an elongated susceptor source (150), wherein the elongated susceptor source includes a spool (152) of elongated susceptor material.

4. The method (200) according to claim 1 or 2, wherein: The extending (210) includes continuously moving the extension portion (156) of the elongated base (154) along an elongated axis of the elongated base at least during the operatively translating (240).

5. The method (200) according to claim 1 or 2, wherein: The extension (156) of the elongated base (154) defines an extension length of at least 0.5 mm and at most 25 mm.

6. The method (200) according to claim 1 or 2, wherein: The extending (210) includes extending in a manner such that the aspect ratio of the extended portion (156) is at least 5 and at most 100.

7. The method (200) according to claim 1 or 2, wherein: The heating (220) includes electrically heating the section (163) of the elongated base (154) by providing an electric current (134) to the section (163) of the elongated base (154) to resistively heat the section (163) of the elongated base (154).

8. The method (200) according to claim 1 or 2, wherein: The heating (220) includes heating the segment (163) of the elongated base (154) from an ambient temperature to the segment temperature in less than a threshold heating time of at most 3 seconds.

9. The method (200) according to claim 1 or 2, wherein: The pressing (230) includes melting a melt region of the thermoplastic body (40) via heat transfer from the heating portion (164) of the elongated base (154).

10. The method (200) according to claim 9, wherein: After said smoothing, said method (200) further comprises the step of cooling (250) said molten region to solidify said molten region and maintain the embedded length of said elongated base (154) within said thermoplastic body (40).

11. The method (200) of claim 9, wherein: The melting region defines a maximum melting region cross-sectional extent (46) measured perpendicular to the elongated axis of the melting region, wherein the front region (166) of the heating portion (164) of the elongated base (154) defines a maximum base cross-sectional dimension (158) measured perpendicular to the elongated axis of the melting region, and further, wherein the melting includes melting in a manner such that a ratio of the maximum melting region cross-sectional extent (46) to the maximum base cross-sectional dimension (158) is at most 5.

12. The method (200) according to claim 1 or 2, wherein: The elongated base (154) includes at least one of a conductive material, a metal, and a ferromagnetic material.

13. The method (200) according to claim 1 or 2, wherein: The elongated base (154) includes an elongated wire.

14. The method (200) according to claim 1 or 2, wherein: The elongated base (154) includes an electrical insulator coating an outer surface of the elongated base (154), and further wherein the method (200) includes the step of performing the heating (220) without melting the electrical insulator.

15. The method (200) according to claim 1 or 2, wherein: The method (200) comprises the steps of performing at least the stretching (210), the heating (220), the pressing (230), the operatively translating (240) and the smoothing without distorting the thermoplastic body (40).

16. The method (200) according to claim 1 or 2, wherein: The thermoplastic body (40) has a thickness (52) that is less than five times the maximum base cross-sectional dimension (158) of the elongated base (154).

17. The method (200) according to claim 1 or 2, wherein: The method (200) further includes the step of repeating (260) the extending (210), the heating (220), the pressing (230), and the operatively translating (240) at least a plurality of times to embed a plurality of lengths of the elongated base (154) within the thermoplastic material (48).

18. A system (10) for embedding a length of an elongated base (154) into a thermoplastic body (40), the system comprising: An application tool (100), the application tool (100) comprising: (i) a guide structure (110) configured to guide the elongated base (154); (ii) a body contact structure (120) configured to contact a body surface (42) of the thermoplastic body (40); and (iii) a heating structure (130) configured to heat a section (163) of the elongated base (154); a translation structure (20) configured to operatively translate the applicator tool (100) and the thermoplastic body (40) relative to each other along an embedding path (60) of the elongated base (154); and A controller (30) programmed to control the operation of the applicator tool (100) and the translation structure (20) according to the method (200) of claim 1 or 2.

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