Thermoplastic Aerospace Patch Repair With a Moving Ultrasonic Horn

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Solution Overview

Problem

Existing ultrasonic welding methods for thermoplastic materials in aerospace components lack efficiency and speed, particularly in creating continuous, elongated welds that maintain structural integrity and aerodynamic shape.

Innovation Solution

A method involving continuous ultrasonic welding of a thermoplastic patch to a thermoplastic aerospace component using an ultrasonic horn, where the horn is moved along a weld path to create a continuous elongated weld, optionally with a thermoplastic film interposed between the components, ensuring thorough fusion and rapid repair.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional ultrasonic welding methods are used for thermoplastic aerospace components, then welding can be achieved, but welding speed is slow and efficiency is low

Engineering Contradiction:

Improvewelding speedVSAvoidrepair time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The welding process is segmented into discrete controllable phases (heating, welding, cooling) that can be optimized independently. The horn moves through discrete positions along the weld path, allowing precise control of heat application and weld formation at each segment, thereby increasing overall welding speed and efficiency.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The ultrasonic horn is made dynamically movable along the weld path rather than being stationary. This dynamic positioning allows continuous welding progression along the thermoplastic patch, significantly increasing welding speed compared to traditional static or step-by-step welding methods.

Inventive Principle:

Principle #15Dynamics

2Shape

If traditional welding methods are used, then welding can be completed, but the aerodynamic shape of the component may be compromised

Engineering Contradiction:

Improveaerodynamic shapeVSAvoidweld quality

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

The welding process applies localized heating and pressure only at the specific weld location through the movable horn, preserving the aerodynamic shape of the surrounding component. The thermoplastic patch is welded in place without requiring component disassembly or reshaping, maintaining original aerodynamic contours.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The thermoplastic patch is pre-positioned and aligned on the aerospace component before welding begins. This preliminary positioning ensures that the patch conforms to the component's aerodynamic shape, and the subsequent welding process simply fuses the materials without altering the pre-established geometric relationship.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If continuous ultrasonic welding is used with horn movement, then welding speed increases, but process complexity increases

Engineering Contradiction:

Improvewelding speedVSAvoidwelding system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The ultrasonic horn serves multiple functions: it applies ultrasonic vibration for welding, provides mechanical pressure through its weight and actuation force, and acts as a heating element through frictional heat generation. This multi-functionality reduces the need for separate heating devices, pressure application mechanisms, and welding tools, thereby limiting the increase in overall system complexity despite the continuous welding capability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

Facilitates rapid, efficient, and structurally sound repairs of thermoplastic aerospace components with minimal impact on nearby structures, preserving aerodynamic shapes and enhancing weld speed up to twice as fast as traditional methods.

Implementation Method 1

An ultrasonic horn is arranged on the thermoplastic patch... The thermoplastic patch is ultrasonic welded to the thermoplastic aerospace component using the ultrasonic horn

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Implementation Method 2

The thermoplastic patch is vertically between the thermoplastic aerospace component and the ultrasonic horn... providing a continuous elongated weld

Methodology Applied

Scientific EffectFrictional heating: Viscous Heating

Data Source

PatentUS20250312981A1Continuous ultrasonic welding thermoplastic material for aerospace component repair

Publication Date: 2025.10.09 ROHR INC

AI summary

A repair method is provided during which a thermoplastic patch is arranged on a thermoplastic aerospace component. An ultrasonic horn is arranged on the thermoplastic patch. The thermoplastic patch is vertically between the thermoplastic aerospace component and the ultrasonic horn. The thermoplastic patch contacts the ultrasonic horn. The thermoplastic patch is continuous ultrasonic welded to the thermoplastic aerospace component using the ultrasonic horn.