Induction Welding Susceptor Removal for Composite Joints
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Solution Overview
Problem
Current thermoplastic composite welding processes are limited by the need for extensive tooling, slow welding times, and the inclusion of 'fly-away' heating elements that add weight and complexity to the final product, hindering the widespread use of composite materials in applications like aircraft manufacturing.
Innovation Solution
A thermoplastic welding apparatus and method utilizing induction coils to generate a magnetic flux that heats susceptors positioned along joint lines, allowing for rapid and controlled bonding of composite parts without the need for these elements to remain in the final product, using a susceptor removal device to extract the susceptors after heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional thermoplastic welding processes are used, then welding can be achieved, but extensive tooling is required and welding times are slow
Solution Approach 1:
The patent replaces traditional mechanical heating systems and extensive tooling with an electromagnetic induction system. Induction coils generate a magnetic flux that induces eddy currents in the susceptor material, converting electromagnetic energy directly into heat at the weld zone. This substitution of mechanical heating with electromagnetic heating achieves rapid welding without requiring complex mechanical tooling.
Solution Approach 2:
The patent introduces a susceptor (intermediary material) that is positioned between the thermoplastic components to be welded. The susceptor absorbs the magnetic flux energy and converts it to heat, which then melts the thermoplastic material at the joint lines. This intermediary approach allows for localized, rapid heating without requiring the entire assembly to be heated or requiring extensive tooling.
2Productivity
If heating elements are positioned between composite parts during induction welding, then rapid welding is achieved, but the heating elements become part of the final composite piece adding weight and complexity
Solution Approach 1:
The patent extracts or removes the susceptor (heating element) from the final composite structure after it has served its purpose. The susceptor is introduced temporarily to enable rapid induction welding, then removed from the joint lines before the thermoplastic fully solidifies. This allows the benefits of rapid induction welding to be achieved without the penalty of permanent heating elements remaining in the final product, thus reducing weight and complexity.
3Productivity
If heating elements are positioned between composite parts during induction welding, then rapid welding is achieved, but design complexity increases
Solution Approach 1:
The susceptor is removed from the joint lines after heating, preventing it from becoming a permanent feature in the final composite design. This extraction eliminates the need to design around permanent heating elements, maintaining design flexibility and simplicity while still achieving rapid welding during the manufacturing process.
Solution Approach 2:
The susceptor functions as a disposable, single-use component that is introduced temporarily for the welding process and then removed. It serves its heating function and is discarded, rather than being incorporated into the final product. This approach allows for rapid welding without permanently complicating the design, as the susceptor does not need to be accounted for in the final structure.
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
Enables rapid, reliable, and cost-effective thermoplastic welding of composite components, such as aircraft parts, without residual 'fly-away' elements, improving production efficiency and reducing material weight and complexity.
Implementation Method 1
generating a magnetic flux using a plurality of induction coils to cause the susceptor to heat the one or more joint lines between the first and second thermoplastic composite parts
Implementation Method 2
The susceptor is configured to heat the one or more joint lines when exposed to a magnetic flux generated by the plurality of induction coils
Implementation Method 3
a thermoplastic weld is created when the thermoplastic material on the surface of two thermoplastic composite components is heated to the melting or softening point and the two surfaces are brought into contact so that the molten thermoplastic mixes
Implementation Method 4
the surfaces are held in contact while the thermoplastic cools below the softening temperature to fuse into the thermoplastic weld
Data Source
AI summary
An apparatus for thermoplastic welding includes at least one tool configured to support first and second thermoplastic composite parts in a first welding position having one or more joint lines between the first and second thermoplastic composite parts. The tool includes a plurality of induction coils. The apparatus further includes a susceptor removably positioned along the one or more joint lines. The susceptor is configured to heat the one or more joint lines when exposed to a magnetic flux generated by the plurality of induction coils to bond the first and second thermoplastic composite parts along the one or more joint lines. The apparatus also includes a susceptor removal device coupled to the susceptor and configured to remove the susceptor during bonding of the first and second thermoplastic composite parts.