Flux Director for Induction Welding Thermoplastic Composites
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Solution Overview
Problem
Induction welding of composite components with electrically conductive fibers, such as graphite, experiences undesirable heating when the components are not parallel to the magnetic flux, particularly at frequencies above 30 KHz, leading to inefficient and potentially damaged composite structures.
Innovation Solution
A tool with a flux director and induction coils, where the flux director is formed of magnetically opaque materials to redirect and focus the magnetic flux, ensuring it is parallel to the welding surface while blocking it from non-parallel areas, using smart susceptors to generate heat only at desired locations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If induction welding is performed at frequencies above 30 KHz, then welding efficiency is improved, but undesirable heating occurs in composite materials with electrically conductive fibers
Solution Approach 1:
A flux director made of magnetically opaque material is introduced as an intermediary component between the induction coil and the composite workpiece. This flux director mediates the magnetic flux distribution, directing it parallel to the welding surface and preventing perpendicular penetration that causes eddy current heating in conductive fibers, thereby enabling high-frequency welding without harmful heating effects
2Temperature
If the magnetic flux is directed perpendicular to the composite component, then induction heating occurs, but this causes heating at locations other than the welding surface
Solution Approach 1:
The flux director creates localized magnetic flux paths that are tailored to specific welding locations. By shaping the magnetically opaque material into specific geometries (such as channels or patterns), the magnetic flux is concentrated and directed parallel to the welding surface at precise locations, ensuring heating occurs only where needed and not in surrounding areas
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 solution effectively reduces unwanted heating in composite structures during welding, improving the quality and efficiency of the process by focusing heat on joints and minimizing rework, thereby lowering manufacturing costs and time.
Implementation Method 1
the base is formed of a material that is magnetically opaque to a frequency in a range of 30 KHz to 350 KHz
Implementation Method 2
A magnetic flux is generated using a plurality of induction coils of a tool
Implementation Method 3
induction welding processes may be used. The composite components may be placed substantially parallel to the magnetic flux during induction welding processes
Data Source
AI summary
A method and apparatus for welding a thermoplastic structure. The apparatus comprises a base, a cover, and a channel. The base is formed of a material that is magnetically opaque to a frequency in a range of 30 KHz to 350 KHz. The cover is formed of the material. The channel extends between the base and the cover.