Vibration Welding of Hollow Thermoplastic Flanges Without Internal Supports
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Solution Overview
Problem
Current welding techniques for aircraft components, particularly hollow fiber-reinforced thermoplastic structures, are time-consuming and costly due to the need for complex processes and internal supporting devices, which increase tooling costs and limit the variety of structures that can be manufactured.
Innovation Solution
A method involving a first component with a base portion and a flange, where the flange is biased against a second component by applying a load and vibrating one of the components to form a weld joint, eliminating the need for internal devices and allowing for the formation of hollow structures without the use of hard blocks or bladders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional welding techniques (resistance welding, induction welding, ultrasonic welding, laser welding) are used for aircraft structures, then weld strength and reliability can be achieved, but capital investment is high and welding time is long (minutes to tens of minutes per weld)
Solution Approach 1:
The patent applies vibration welding technique where one component is vibrated relative to the other during welding. The vibration generates friction heat at the interface and facilitates rapid welding of thermoplastic materials, reducing welding time from minutes to seconds while maintaining reliable weld joints for aircraft structures
2Force
If internal supporting devices (hard blocks or bladders) are used during hollow structure formation, then weld load can be provided, but tooling costs increase and welding cycle time increases due to insertion and removal steps
Solution Approach 1:
The patent designs the hollow structure components themselves to provide the necessary weld load during vibration welding. The component geometry and material properties are engineered to generate sufficient reaction force, eliminating the need for separate internal supporting devices and their associated tooling complexity and cycle time
Solution Approach 2:
The patent removes the internal supporting devices (hard blocks or bladders) from the welding process by designing components that self-generate the required weld load, simplifying the overall tooling system and reducing manufacturing complexity
3Force
If internal supporting devices are used in hollow structure formation, then weld load can be maintained, but the variety of manufacturable hollow structures is limited and formation complexity increases
Solution Approach 1:
The patent varies component design parameters such as wall thickness, geometry, and material properties to optimize self-generated weld load for different hollow structure applications, enabling greater design freedom and structural variety without requiring internal supporting devices
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 method reduces tooling costs, simplifies the welding process, and expands the range of hollow structures that can be manufactured by eliminating the need for internal supporting devices, thereby decreasing formation time and complexity.
Implementation Method 1
the flange is biased against the second component by a reaction of the first component to the load
Implementation Method 2
vibrating one of the first and the second components to form a weld joint
Implementation Method 3
vibrating one of the first and the second components to form a weld joint between at least a part of the second component and at least a part of the flange
Data Source
AI summary
A method of forming a weld joint is provided. A first component having a base portion and a flange extending from the base portion is provided. A second component is provided. The second component and the flange are brought into abutment and a load is applied to the flange via the second component. The flange is biased against the second component by a reaction of the first component to the load. One of the first and the second components is vibrated to form a weld joint between at least a part of the second component and at least a part of the flange.