Thermoplastic Acoustic Panel Welding Thermal Gradient
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Solution Overview
Problem
Existing acoustic attenuation structures face limitations in size due to manufacturing constraints, such as the need for large-sized acoustic panels, which are difficult to produce without reducing acoustic performance or increasing bulk, and the challenge of maintaining component geometry during welding.
Innovation Solution
A method involving the welding of thermoplastic acoustic components with a thermal gradient applied during the welding process, where the joining edges are heated above the glass transition or melting temperature, while the rest of the components are kept below the geometric stabilization temperature, using a smaller welding tooling to prevent deformation and reduce the need for extensive holding tooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If acoustic components are assembled by welding with significant heating, then the components are joined together, but thermal diffusion causes heating of parts away from the junction leading to deformation and uncontrolled geometry modification
Solution Approach 1:
The patent applies local quality by creating a thermal gradient where only the joining edges are heated to welding temperature while other parts of the acoustic components remain at lower temperatures. This is achieved through controlled heating methods that localize thermal energy at the junction zones, preventing thermal diffusion to distant parts and thus avoiding deformation and geometry modification of the hollow acoustic elements.
Solution Approach 2:
The patent utilizes parameter changes by controlling the temperature distribution across the acoustic components during welding. By maintaining different temperature zones (high temperature at joining edges, low temperature at distant parts), the process enables welding while preserving geometric stability. The temperature parameters are carefully managed to stay below the geometric stabilization temperature threshold for non-heated regions.
2Manufacturing precision
If large-dimensioned holding toolings are used to maintain geometry during welding, then component geometry is preserved, but the size of achievable acoustic structures is limited by the dimensions of the holding tooling
Solution Approach 1:
The invention replaces extensive holding tooling with localized thermal control. Instead of constraining the entire acoustic component with large tooling, the process applies heat only locally at the joining edges while keeping the rest of the component cool. This localized approach eliminates the need for large-dimensioned holding toolings and allows welding of much larger acoustic structures than the tooling dimensions would permit.
Solution Approach 2:
The patent substitutes the mechanical holding system with a thermal control system. Rather than using physical constraints and large toolings to prevent deformation, the process uses controlled thermal gradients to prevent thermal diffusion to distant parts. This replacement of mechanical restraint with thermal management enables the welding of larger structures without proportionally larger tooling.
3Strength
If fixing systems with bores are used to assemble acoustic components, then the components are secured together, but the functional surface for acoustic attenuation is reduced and bulk is increased
Solution Approach 1:
The patent replaces mechanical fixing systems (bores, fasteners, etc.) with a welding process that joins acoustic components directly. This substitution eliminates the need for separate fixing elements that would occupy space on the functional acoustic surface. The welding process creates strong joints without requiring additional bulk or reducing the acoustic attenuation area, as the joining is achieved through material fusion rather than mechanical insertion.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the production of large-sized acoustic panels with maintained acoustic performance and reduced bulk, allowing for easier handling and reuse of welding tooling, while minimizing the need for fixing elements and avoiding component deformation.
Implementation Method 1
a thermal gradient is applied on the parts of the first component and of the second component covered by the tooling so as to apply a temperature higher than the glass transition or melting temperature of the thermoplastic material on the first and second joining edges and so as to apply a temperature lower than or equal to the geometric stabilization temperature of the thermoplastic material on the hollow acoustic elements covered by the tooling that are furthest from the first and second joining edges
Implementation Method 2
the first component and the second component are welded to each other by the first and second joining edges to form at least part of the acoustic panel
Data Source
AI summary
A method for manufacturing an acoustic panel by welding of at least two acoustic components made of thermoplastic material, a thermal gradient being applied on the acoustic components during the welding operation so as to apply a temperature higher than the glass transition or melting temperature of the material on the area to be welded and so as to apply a temperature lower than or equal to the geometric stabilization temperature of the material on the parts furthest from the area to be welded.