Thermoplastic Welded Interfaces Using Shims for Stress-Free Joints
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Solution Overview
Problem
Existing methods for welding thermoplastic components together in aerospace applications are in need of improvement to address dimensional deviations and ensure strong, stress-free joints.
Innovation Solution
A method involving the use of fiber-reinforced thermoplastic shims at the interface between thermoplastic components, which are welded using techniques like vibration, ultrasonic, or induction welding to create strong bonds while accommodating manufacturing tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermoplastic components are welded directly together, then welding strength is improved, but dimensional deviations and internal stress cause warping and deformation
Solution Approach 1:
A shim made of fiber-reinforced thermoplastic composite material is introduced as an intermediary component between the skin and support member. The shim fills dimensional gaps and accommodates manufacturing tolerances, allowing the skin and support member to be welded together through the shim without direct contact. This intermediary layer reduces internal stress and prevents warping while maintaining weld strength.
Solution Approach 2:
The welding interface is segmented into three distinct components: the skin, the shim, and the support member. By dividing the direct weld interface into multiple segments, the system can accommodate dimensional variations in each component independently while maintaining overall structural integrity and weld strength.
2Manufacturing precision
If shims are used to accommodate dimensional deviations, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The shim is made from the same fiber-reinforced thermoplastic composite material as the skin and support member, ensuring material homogeneity throughout the structure. This allows all components to be processed using the same manufacturing techniques and welded using the same methods, simplifying the overall manufacturing process despite the additional component.
Solution Approach 2:
The shim serves multiple functions simultaneously: it accommodates dimensional gaps, provides a welding interface, reduces internal stress, and maintains structural integrity. By consolidating these multiple functions into a single component, the overall device complexity is minimized.
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
The method ensures precise fitting and strong welds without deformation, reducing internal stress and warping in aircraft structures by using shims to bridge gaps and facilitate uniform welding.
Implementation Method 1
The welding includes vibration welding, ultrasonic welding and/or induction welding
Implementation Method 2
The welding includes vibration welding, ultrasonic welding and/or induction welding
Implementation Method 3
The welding includes vibration welding, ultrasonic welding and/or induction welding
Data Source
AI summary
A method is provided for joining thermoplastic components. During this method, a skin is provided that is configured from or otherwise includes a skin fiber-reinforced thermoplastic composite. A support member is provided that is configured from or otherwise includes a support member fiber-reinforced thermoplastic composite. A shim is arranged at an interface between the skin and the support member. The shim is configured from or otherwise includes a shim fiber-reinforced thermoplastic composite. The support member is welded to the skin through the shim at the interface.