Induction Welding Susceptor Layer with Protective Insulation

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Solution Overview

Problem

Induction welding using susceptor wires and large induction coils often forms undesirable current paths, leading to overheating and inconsistencies in the workpiece, which can result in burns and unwanted thermal inconsistencies.

Innovation Solution

A method and apparatus that incorporates a susceptor layer and protective layers positioned between the susceptor and workpieces to prevent the formation of undesired current paths during induction heating, utilizing fiberglass layers to interrupt these paths and ensure controlled heating.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If susceptor wires and large induction coils are used for induction welding, then welding capability is achieved, but undesirable current paths form causing overheating and inconsistencies in the workpiece

Engineering Contradiction:

Improvewelding capabilityVSAvoidoverheating and thermal inconsistencies

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

A susceptor layer is introduced as an intermediary between the induction coil and the workpiece. This susceptor layer is specifically designed to guide electromagnetic energy to the weld zone while preventing formation of undesirable current paths through the workpiece, thereby eliminating overheating and thermal inconsistencies while maintaining welding capability

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The susceptor layer is applied locally at the weld zone rather than uniformly across the entire workpiece. This localized application ensures that electromagnetic energy is concentrated precisely where welding is needed, preventing unwanted heating in other areas while maintaining effective welding capability

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

Prevents overheating and inconsistencies by blocking unwanted current paths, allowing for precise and controlled induction welding of workpieces without thermal damage, thereby improving the quality of the weld.

Implementation Method 1

an induction coil that is energized with a radio frequency electric current, which in turn, generates a high-frequency electromagnetic field

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

the heating may take the form of resistive heating that occurs due to induced currents, referred to as eddy currents

Methodology Applied

Scientific EffectEddy currents: Eddy Currents

Implementation Method 3

The number of protective layers is configured to prevent an undesired current path from forming at the weld location during induction heating

Methodology Applied

Scientific EffectElectromagnetic shielding:

Data Source

PatentUS9868249B2Induction welding system

Publication Date: 2018.01.16 THE BOEING CO

AI summary

A method and apparatus for performing induction welding. A number of protective layers are positioned between a susceptor layer and at least one of a plurality of workpieces at a weld location. An undesired current path is prevented from forming at the weld location during induction heating of the plurality of workpieces by the number of protective layers.