Hybrid Polymeric Joint With Weldable Thermoset Interface

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Solution Overview

Problem

Conventional methods for joining thermoset and thermoplastic materials in gas turbine engine components face challenges due to low surface free energy of thermoplastics, requiring surface preparation and long curing times, and mechanical fasteners add weight and cause stress concentration.

Innovation Solution

A hybrid polymeric component with a thermoset portion and thermoplastic portion joined by a welded joint, featuring a thermoplastic interlayer and thermal barrier to facilitate fusion bonding, eliminating the need for mechanical fasteners and adhesives.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If mechanical fasteners are used to join thermoset and thermoplastic materials, then the components can be assembled, but weight increases and stress concentration occurs

Engineering Contradiction:

Improvejoint strengthVSAvoidcomponent weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent replaces mechanical fastening systems with a welding process. A thermoplastic interlayer is applied to the thermoset component surface, and both components are joined through welding without mechanical fasteners. This substitution eliminates the weight penalty and stress concentration associated with mechanical fasteners while achieving strong joint bonding.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If adhesives are used to join thermoset and thermoplastic materials, then bonding can be achieved, but curing time increases

Engineering Contradiction:

Improvebond strengthVSAvoidcuring time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The patent replaces adhesive bonding with a welding process. The thermoplastic interlayer is welded to join the thermoset and thermoplastic components, eliminating the long curing times associated with adhesive systems. The welding process achieves bonding rapidly without requiring extended curing periods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If surface preparation is performed on thermoplastic materials to improve bonding, then adhesion can be enhanced, but manufacturing complexity increases

Engineering Contradiction:

Improvesurface adhesionVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent replaces adhesive bonding (which would require surface preparation) with welding. The thermoplastic interlayer is directly welded to the thermoset component surface without requiring chemical treatments, abrasion, or other surface preparation steps. This substitution simplifies the manufacturing process while achieving strong bonding.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Strength

If thermoplastic material is directly joined to thermoset material, then bonding can be achieved, but thermal damage occurs to the thermoset material

Engineering Contradiction:

Improvejoint bondingVSAvoidthermal damage to thermoset

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a thermoplastic interlayer as an intermediary between the thermoset and thermoplastic components. This interlayer serves as a mediator that can be welded without damaging the thermoset material, as the welding process affects only the thermoplastic interlayer and the opposing thermoplastic component, not the heat-sensitive thermoset substrate.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent applies a thermoplastic interlayer only at the specific bonding interface where welding is required. This localized application of thermoplastic material allows welding to occur at the joint interface without subjecting the entire thermoset component to welding temperatures, thereby protecting the thermoset material from thermal damage while achieving the necessary joint bonding.

Inventive Principle:

Principle #3Local quality

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

The solution provides lightweight, high-performance components with improved bonding and reduced stress concentration, while maintaining thermal insulation and mechanical support.

Implementation Method 1

joining a thermoplastic portion to the thermoset portion by welding the thermoplastic portion to the weldable surface

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 2

facilitate fusion bonding

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

a thermal barrier between the thermoset material and the thermoplastic material... the thermal barrier comprises ceramic or polymeric fibers

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS12533756B2Polymeric component and method of making the same

Publication Date: 2026.01.27 RTX CORP

AI summary

A thermoset component for joining with a thermoplastic component according to an exemplary embodiment of this disclosure, among other possible things includes a thermoset material, a weldable surface on the thermoset material, and a thermal barrier. The weldable surface includes a thermoplastic material. A hybrid polymeric component and a method of making a hybrid polymeric component are also disclosed.