Thermoplastic Composite Welding Geometry Correction

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Solution Overview

Problem

Large-sized vehicle components made from fiber-reinforced plastics often exhibit shape deviations due to differences in cooling rates and fiber orientation, leading to undulations and the need for additional material application to correct these issues, which can increase weight and complexity, particularly in aircraft manufacturing.

Innovation Solution

A method using thermoplastic materials with reinforcement fibers for producing vehicle components, allowing for reversible curing and local re-warming to correct geometry deviations, eliminating the need for riveted connections and minimizing warming-induced undulations by targeted heating and cooling processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If additional thin layers of material are applied to correct shape deviations, then surface quality is improved, but component weight increases

Engineering Contradiction:

Improvesurface qualityVSAvoidcomponent weight

Core Design Contradiction:

Manufacturing precisionVSWeight of moving object

Solution Approach 1:

The patent applies preliminary corrective action by re-warming the joining zone after initial cooling to adjust and correct shape deviations before final cooling. This preliminary correction eliminates the need for additional material layers, thereby improving surface quality without increasing component weight.

Inventive Principle:

Principle #10Preliminary action

2Strength

If riveted connections are used to join components, then structural strength is improved, but visible surface defects are created

Engineering Contradiction:

Improvestructural strengthVSAvoidsurface quality

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent merges the stiffening component and skin panel into a single integrated structure through welding in the joining zone. This eliminates the need for separate riveted connections, providing both structural strength and a smooth, defect-free outer surface.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces the mechanical riveting system with a thermal welding process. By using heat to fuse the thermoplastic materials directly, the connection achieves structural strength without the mechanical fasteners that would create visible surface defects.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If different layer thicknesses are used in parisons, then structural functionality is improved, but cooling rate differences cause shape deviations

Engineering Contradiction:

Improvestructural functionalityVSAvoidshape accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent changes the thermal parameter by re-warming the joining zone after initial cooling. This allows adjustment of the shape despite different layer thicknesses, maintaining both structural functionality and shape accuracy by compensating for differential cooling effects.

Inventive Principle:

Principle #35Parameter changes

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 enables the production of high-quality, lightweight components with reduced surface irregularities and eliminates the need for additional material application, achieving a monolithic connection without rivets and minimizing thermal stresses through controlled heating and cooling.

Implementation Method 1

The suitable thermoplastic materials for realizing the matrix may comprise PPS (polyphenylene sulphide), PEEK (polyether ether ketone), PEKK (polyether ketone ketone) or others

Methodology Applied

Scientific EffectPhase change: Phase Change

Implementation Method 2

of areally warming a joining zone in which the connection surface of the stiffening component and the mounting portion are situated such that the at least one stiffening component and the at least one skin panel are welded to one another

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 3

of cooling the joining zone

Methodology Applied

Scientific EffectCooling: Cooling

Implementation Method 4

Different layer thicknesses can give rise to different rates of cooling after the warming process. For example, a stiffening component has not yet completely cooled in a connection region while adjacent skin panels without stiffening component have already completely cooled. This can give rise to different expansions

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS10987877B2Method for producing a vehicle component from a fiber-reinforced plastic

Publication Date: 2021.04.27 AIRBUS OPERATIONS GMBH

AI summary

A method for producing a vehicle component from a fiber-reinforced plastic including providing a skin panel having an inner side, outer side and mounting portion. The skin panel is a fiber-reinforced thermoplastic material. At least one stiffening component has a connection surface. The stiffening component is a fiber-reinforced thermoplastic material. The stiffening component and skin panel are contacted wherein the connection surface lies on the mounting portion. The method includes areally warming a joining zone so the stiffening component and skin panel are welded together. The joining zone is cooled. A determined geometry of the combination of stiffening component and skin panel is compared with a predefinable geometry. The joining zone is re-warmed, deforming the stiffening component and the skin panel, and the method includes cooling in order to attain the predefinable geometry if the determined geometry deviates from the predefinable geometry.