Induction Welding Cooling for Smooth Thermoplastic Composite Surfaces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional induction welding methods for thermoplastic composites face challenges such as high magnetic field intensity leading to surface deformations, costly and complex tooling requirements, and alteration of part composition, especially for aerodynamic components like fuselages and wings.
Innovation Solution
A method and system that uses air or gas flow through openings in tooling to actively cool and press composite parts during induction welding, preventing surface deformations and eliminating the need for complex tooling by using a porous material and induction heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If matched tooling with high tolerances is used to prevent surface deformation during welding, then surface integrity is improved, but manufacturing cost and complexity increase significantly
Solution Approach 1:
The patent replaces the mechanical cooling system (liquid-cooled tooling) with a pneumatic cooling system (air or gas flow through openings). This substitution eliminates the need for complex liquid cooling channels and reduces tooling complexity while maintaining effective cooling to prevent surface deformation during welding.
Solution Approach 2:
The patent extracts the cooling function from the tooling structure by introducing separate air or gas flow through openings in the tooling. This separates the cooling system from the tooling itself, allowing the tooling to maintain high tolerances without the added complexity of integrated liquid cooling channels.
2Manufacturing precision
If liquid-cooled tooling is used to prevent surface deformation, then surface integrity is improved, but risk of contamination and system complexity increase
Solution Approach 1:
The patent uses pneumatic cooling (air or gas flow) instead of hydraulic cooling (liquid). This eliminates the risk of liquid contamination while maintaining effective heat removal. The air or gas flows through openings in the tooling to cool the composite part surface without contact with the weld zone.
Solution Approach 2:
The patent removes the liquid cooling system entirely and replaces it with a separate pneumatic cooling system. This extraction of the cooling function from the tooling structure eliminates contamination risks associated with liquid leaks while maintaining surface integrity through effective cooling.
3Strength
If induction heating is applied to melt thermoplastic matrix, then welding strength is improved, but surface deformation occurs without adequate cooling
Solution Approach 1:
The patent applies cooling action before and during the heating process. Air or gas flow is established through openings in the tooling prior to and during induction heating, pre-cooling the surface and maintaining it throughout the welding process. This preliminary cooling action prevents surface deformation while allowing the weld zone to reach melting temperature.
Solution Approach 2:
The patent creates different thermal conditions in different zones: the weld zone receives full induction heating to achieve melting and bonding, while the surface zones are actively cooled through air or gas flow to prevent deformation. This local differentiation of thermal treatment allows simultaneous achievement of welding strength and surface integrity.
4Force
If air or gas flow is used to press the first composite part toward the second, then consolidation pressure is achieved, but additional system complexity is introduced
Solution Approach 1:
The patent makes the air or gas flow system perform multiple functions: it cools the surface to prevent deformation, presses the composite parts together to provide consolidation pressure, and maintains part alignment. This multi-functionality eliminates the need for separate cooling and pressing systems, reducing overall system complexity.
Solution Approach 2:
The patent combines the cooling function and consolidation pressure function into a single air or gas flow system. The same pneumatic system that cools the surface also provides the necessary pressing force, merging two functions into one integrated system and reducing overall complexity.
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
Ensures smooth, aerodynamic surfaces and prevents deconsolidation by applying equal and opposite forces during welding, reducing costs and complexity while maintaining part composition integrity.
Implementation Method 1
The end effector may have an induction coil that generates an alternating magnetic field, which generates eddy currents in the conductive fibers of the composite material that in turn melts the thermoplastic matrix
Implementation Method 2
generates eddy currents in the conductive fibers of the composite material that in turn melts the thermoplastic matrix
Implementation Method 3
induction welding using an end effector placed near the thermoplastic composite joint
Implementation Method 4
providing a flow of air or gas through the at least one opening, with the flow of air or gas impinging on a bottom surface of the first composite part
Data Source
AI summary
A method for welding thermoplastic composite parts while actively cooling includes placing a first composite part onto a surface of a tooling, placing a second composite part onto the first composite, pressing the second composite part toward the first composite part with an induction welding end effector, and providing a flow of air or gas through an opening extending through the shaping surface while induction welding the second composite part to the first composite part. The first composite is sandwiched between the surface of the tooling and the second composite. The flow of air or gas impinges on a bottom surface of the first composite part and is sufficient to press the first composite part toward the second composite part. Induction welding the second composite part to the first composite part is performed by applying induction heating while the flow of air is provided through the at least one opening.