U-Shaped Ferrite Induction Welding Coil for Composite Joints
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Solution Overview
Problem
Conventional induction welding processes for composite materials, such as thermoplastics, face challenges in achieving uniform and rapid heating when using induction welding coils on one side, leading to longer welding times and potential overheating issues due to geometrical constraints and limited access in aircraft manufacturing.
Innovation Solution
The use of a customizable induction welding coil with ferrite cores and smart susceptor wires that focus magnetic flux for optimized heating, allowing for rapid and uniform heating of thermoplastic joints from one side, even in complex geometries, by configuring the coil's spine, prongs, and auxiliary pieces to guide magnetic flux and varying susceptor wire density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional induction welding coils are used on one side of composite components, then the welding process can be performed with limited access, but the heating becomes uneven and welding time increases
Solution Approach 1:
The patent applies local quality by varying the density of susceptor wires in different regions of the welding coil. Areas that heat up faster have lower susceptor wire density, while areas that heat up slower have higher susceptor wire density. This non-uniform distribution compensates for the uneven heating caused by single-sided coil placement, achieving uniform heating across the weld zone without increasing welding time.
Solution Approach 2:
The patent changes the physical parameters of the induction welding system by introducing susceptor wires with specific magnetic properties and varying their density. This modifies the magnetic flux distribution and heating characteristics, enabling uniform heating from a single-sided coil configuration and resolving the contradiction between accessibility and productivity.
2Reliability
If lower power settings are used to prevent overheating, then overheating risk is reduced, but welding time increases
Solution Approach 1:
The patent uses local quality by distributing susceptor wires non-uniformly to create zones with different heating rates. This allows the system to maintain lower overall power settings while ensuring that even the slowest-heating areas receive sufficient energy, preventing both overheating and excessive welding time.
Solution Approach 2:
The patent applies partial action by using susceptor wires only in specific regions where additional heating is needed, rather than uniformly throughout the entire coil. This targeted approach allows lower power settings overall while still achieving the necessary heating in critical areas, maintaining reliability without sacrificing productivity.
3Manufacturing precision
If coils are placed on both sides of composite components, then uniform heating is achieved, but accessibility is limited in complex geometries
Solution Approach 1:
The patent resolves this contradiction by applying local quality through non-uniform susceptor wire distribution. This allows a single-sided coil configuration to achieve heating uniformity that would normally require dual-sided placement, making the process accessible in complex geometries while maintaining manufacturing precision.
Solution Approach 2:
Instead of placing coils on both sides to achieve uniform heating, the patent inverts the approach by placing a single coil on one side and using susceptor wires to create the uniform heating effect. This reverses the conventional wisdom and achieves the same result with improved accessibility.
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 approach enables efficient and uniform induction welding of composite parts, reducing welding time and preventing overheating, while allowing for welding in previously inaccessible areas, such as those found in aircraft construction.
Implementation Method 1
customizable induction welding coil with ferrite cores and smart susceptor wires that focus magnetic flux for optimized heating
Implementation Method 2
induction welding coil comprising a spine having a planar body with opposing ends, and a pair of prongs extending perpendicularly from the opposing ends of the spine
Implementation Method 3
rapid and uniform heating of thermoplastic joints from one side, even in complex geometries
Data Source
AI summary
An induction welding coil includes a spine having a planar body with opposing ends, and a pair of prongs extending perpendicularly from the opposing ends of the spine. Each of the prongs has a planar body, wherein the spine and the pair of prongs are formed from a ferrite material to define a ferrite core. The induction welding coil further includes a coil wire having a plurality of winding that surround the planar body of the spine.