Blind Welding of Thermoplastic Composites With Segmented Susceptors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current techniques for welding thermoplastic composite components face challenges in creating blind welds, where applying opposing forces is not possible, leading to increased component collapse and deformation.
Innovation Solution
A method involving an interface layer between thermoplastic composite components, using an electromagnetic field and a susceptor to heat the components differently, allowing for blind welding by applying force to one side and controlling the weld pool through an induction process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If opposing force is applied to both sides of components to create a weld path, then welding reliability is improved, but the method cannot be used for blind welds where access to one side is unavailable
Solution Approach 1:
The patent replaces the mechanical opposing force system with an electromagnetic field system. Instead of applying mechanical force from both sides to create material collapse and a weld path, the invention uses electromagnetic induction to heat the components and create a weld pool, eliminating the need for mechanical access to both sides of the joint.
Solution Approach 2:
The patent introduces an interface layer as an intermediary between the two thermoplastic composite components. This interface layer facilitates heat transfer and material flow during the welding process, enabling blind welds by mediating the interaction between the heated component and the inaccessible component.
2Adaptability or versatility
If electromagnetic field is applied to heat components for blind welding, then blind weld capability is improved, but differential heating of susceptor segments may cause uneven temperature distribution
Solution Approach 1:
The susceptor is divided into multiple segments with different electromagnetic properties. The first susceptor segment has higher permeability than the second segment, allowing differential heating where the first segment reaches melting temperature while the second segment remains below melting temperature. This segmentation enables precise control of the weld pool location and size.
Solution Approach 2:
Different segments of the susceptor are given different local properties (permeability values) to achieve different heating characteristics. The first segment with higher permeability is designed to heat to melting temperature for weld pool creation, while the second segment with lower permeability is designed to stay below melting temperature, creating a controlled thermal gradient.
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
Facilitates blind welds by reducing component deformation and ensuring consistent bonding despite tolerances and surface irregularities, enhancing the welding process efficiency.
Implementation Method 1
applying an electromagnetic field to the central segment and the plurality of lateral segments using an inductor, wherein the central segment and the plurality of lateral segments are configured to respond differently to an application of an EM field
Implementation Method 2
the central segment and the plurality of lateral segments are configured such that the electromagnetic field heats the central segment to the first melting temperature or above, and heats the lateral segments to a temperature below first melting temperature
Implementation Method 3
the interface layer is at or above the third melting temperature
Implementation Method 4
a region of the first thermoplastic composite component aligned with the central segment is at or above the first melting temperature
Implementation Method 5
at least a portion of the second thermoplastic composite component is at or above the second melting temperature
Data Source
AI summary
A method of blind welding thermoplastic composite components is provided. The method includes providing a first and second thermoplastic composite components each having a bonding surface. The first thermoplastic composite component has a first melting temperature and the second thermoplastic composite component has a second melting temperature; providing an interface layer having a third melting temperature; disposing the interface layer between the bonding surfaces; disposing an external susceptor adjacent to the outer surface of the first thermoplastic composite component, wherein the external susceptor includes a central segment and lateral segments that respond differently to an application of an EM field; applying a normal force to the first component external susceptor without an application of an opposing second normal force to the second thermoplastic component; and applying an electromagnetic field to the central and lateral segments using an inductor.