Blind Welding Thermoplastic Composites via Electromagnetic Induction

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Solution Overview

Problem

Current techniques for welding thermoplastic composite components often struggle with blind welds, where opposing forces cannot be applied, leading to difficulties in controlling the weld pool and increased risks of component collapse and deformation.

Innovation Solution

A method and system for blind welding thermoplastic composite components using an interface layer of thermoplastic material between the components, applying a normal force to one component without opposing force, and using an electromagnetic field to create a weld pool, which is then allowed to solidify.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If opposing force is applied to both sides of components during welding, then weld pool control is improved, but the method cannot be used in blind weld scenarios

Engineering Contradiction:

Improveweld pool controlVSAvoidapplicability to blind welds

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

A force application mechanism is introduced as an intermediary element between the welding system and the component being welded. This mechanism applies normal force to the component surface without requiring access to both sides of the joint, enabling blind weld scenarios while maintaining weld pool control through controlled material collapse.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The traditional mechanical system requiring dual-sided force application is replaced with an electromagnetic field-based welding system. The electromagnetic field generates eddy currents within the component material, creating internal heating and material flow that achieves weld pool control without requiring mechanical access to both sides of the joint.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If normal force is applied without opposing force in blind welds, then adaptability to blind weld scenarios is improved, but weld pool control becomes difficult and component collapse risk increases

Engineering Contradiction:

Improvecapability to perform blind weldsVSAvoidweld pool control

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The welding parameters are optimized to achieve effective weld pool control using unidirectional force application. The electromagnetic field parameters (frequency, power, waveform) are specifically tuned to generate appropriate eddy currents that control material flow and weld pool behavior even without opposing mechanical force, preventing component collapse while maintaining welding capability.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The electromagnetic field is applied in controlled periodic cycles, with alternating current waveforms that create rhythmic heating and material flow patterns. This periodic action allows precise control of the weld pool development and material collapse process, achieving reliable welds in blind scenarios through controlled temporal variation of the electromagnetic energy input.

Inventive Principle:

Principle #19Periodic action

3Adaptability or versatility

If electromagnetic field is applied to create weld pool, then welding capability in blind scenarios is improved, but energy consumption increases

Engineering Contradiction:

Improveblind weld capabilityVSAvoidelectromagnetic energy consumption

Core Design Contradiction:

Adaptability or versatilityVSUse of energy by moving object

Solution Approach 1:

The electromagnetic field energy is concentrated and localized precisely at the weld zone through controlled field distribution and shielding. The eddy currents are generated primarily in the immediate vicinity of the welding interface, minimizing energy consumption in surrounding areas and reducing overall energy requirements for blind weld operations.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The electromagnetic field application is maintained continuously throughout the welding process without interruption, ensuring steady-state heating and material flow. This continuous action eliminates the need for repeated heating cycles and maintains efficient energy utilization throughout the weld formation process, reducing total energy consumption compared to intermittent approaches.

Inventive Principle:

Principle #20Continuity of useful action

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

This approach facilitates the creation of strong welds in blind weld scenarios by controlling the weld pool effectively, reducing the risk of component deformation and collapse, and ensuring a robust bond between the thermoplastic composite components.

Implementation Method 1

applying an electromagnetic field to at least portions of the first thermoplastic composite component, the second thermoplastic composite component, and the interface layer while the normal force is applied, and maintaining the application of the electromagnetic field until the at least portions of the first thermoplastic composite component, the second thermoplastic composite component, and the interface layer create a weld pool

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 3

maintaining the application of the electromagnetic field until the at least portions of the first thermoplastic composite component, the second thermoplastic composite component, and the interface layer create a weld pool

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 4

removing the application of the electromagnetic field after the weld pool is created

Methodology Applied

Scientific EffectSolidification: Freezing

Data Source

PatentUS20250026083A1Method and apparatus for joining thermoplastic composite components

Publication Date: 2025.01.23 ROHR INC

AI summary

A method of blind welding thermoplastic composite components is provided that includes: providing a first thermoplastic composite having a FTPC bonding surface, a second thermoplastic composite having a STPC bonding surface, and an interface layer; disposing the interface layer between the FTPC STPC bonding surfaces; applying a normal force to the outer surface of the first thermoplastic composite component; applying an electromagnetic field to at least portions of the first and second thermoplastic composite components and the interface layer while the normal force is applied, and maintaining the application of the electromagnetic field until the first and second thermoplastic composite components and the interface layer create a weld pool; and removing the application of the electromagnetic field after the weld pool is created.