Fiberglass Edge Closeout for Induction Welding Composite Panels
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Solution Overview
Problem
Current composite welding processes, particularly induction welding, face challenges in controlling magnetic flux direction, leading to undesirable heating when composite components are not positioned parallel to the magnetic flux, especially at frequencies above 30 KHz, which affects the efficiency and accuracy of thermoplastic panel fabrication in aircraft manufacturing.
Innovation Solution
The use of a fiberglass composite perimeter edge closeout with dielectric material properties to control and direct magnetic flux, combined with susceptors, allows for controlled directional welding of composite sandwich panels, ensuring efficient bonding of components even when they are not parallel to the magnetic flux, by positioning the fiberglass composite perimeter edge closeout along the edges of the components and using induction coils to generate a magnetic flux that is directed internally within the panel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If induction welding is performed at frequencies above 30 KHz, then welding speed and efficiency are improved, but undesirable heating occurs in the composite material at locations other than the welding surface
Solution Approach 1:
The patent applies local quality by positioning susceptors only at the weld joints where heating is desired. The susceptors are strategically placed between the thermoplastic material of adjacent components at the joint locations, ensuring that induction heating is localized precisely where needed for welding, while preventing unwanted heating in other areas of the composite material.
Solution Approach 2:
The patent uses susceptors as intermediary elements that mediate between the magnetic flux and the thermoplastic material. These susceptors are positioned at the weld joints to concentrate and control the magnetic flux, enabling precise heating control. The susceptors act as intermediaries that convert electromagnetic energy to thermal energy only at the desired welding locations, solving the problem of undesirable heating elsewhere.
2Adaptability or versatility
If composite components are positioned not parallel to the magnetic flux, then adaptability in component positioning is improved, but undesirable heating occurs in the composite material
Solution Approach 1:
The patent applies local quality by placing susceptors specifically at the weld joints regardless of the overall component orientation relative to the magnetic flux. This localized approach ensures that heating occurs only at the joint locations where susceptors are positioned, enabling welding of components in various orientations without causing undesirable heating in non-joint areas.
Solution Approach 2:
The patent changes the spatial distribution parameter by strategically positioning susceptors at specific joint locations rather than uniformly across the component surfaces. This parameter change allows the system to achieve effective welding while controlling heating locations, providing adaptability for components positioned at different angles to the magnetic flux.
3Manufacturing precision
If susceptors are positioned at weld joints to concentrate magnetic flux, then welding precision is improved, but the complexity of the welding process increases
Solution Approach 1:
The patent applies segmentation by dividing the welding process into discrete susceptor placement zones at each joint location. Rather than attempting to control heating across entire component surfaces, the process is segmented into specific joint locations where susceptors are positioned, simplifying the control mechanism while achieving precise welding at each segment.
Solution Approach 2:
The susceptors serve as intermediary elements that simplify the welding process by providing a straightforward mechanism for localized heating. Instead of complex flux distribution systems, the patent uses simple susceptor components positioned at joints, reducing overall process complexity while maintaining high welding precision through the intermediary's flux-concentrating function.
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 method enables rapid, affordable, and repeatable production of thermoplastic sandwich panels with controlled heating at the weld joints, reducing undesirable heating and improving the fabrication of composite components by isolating induced heat to the weld areas, thus enhancing the manufacturing process efficiency and quality.
Implementation Method 1
The fiberglass composite perimeter edge closeout is configured to control directional magnetic flux induced welding by directing the magnetic flux along the edges of the sandwich panel
Implementation Method 2
generating a magnetic flux using the plurality of induction coils to bond the components of the composite sandwich panel
Implementation Method 3
a thermoplastic weld is created when the thermoplastic material on the surface of two composite components is heated to the melting or softening point
Implementation Method 4
the two surfaces are brought into contact so that the molten thermoplastic mixes. Then, the surfaces are held in contact while the thermoplastic cools below the softening temperature to fuse the thermoplastic into the thermoplastic weld
Data Source
AI summary
A composite sandwich panel includes a first composite part and a second composite part. A plurality of stiffeners extend between the first and second composite parts. A fiberglass composite perimeter edge closeout is positioned along one or more edges of the first and second composite parts. The fiberglass composite perimeter edge closeout controls a magnetic flux to bond the first and second composite parts to the plurality of stiffeners.