Welding Thermoplastic Composite Webs Without Radius Fillers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional fabrication techniques for fiber-reinforced thermoplastic composite structures require the use of radius fillers to fill void spaces, which are time-consuming and expensive to produce, and often fail to match the shape and mechanical properties of the void space accurately.
Innovation Solution
The method involves forming fiber-reinforced thermoplastic composite structural members (FRTCSMs) by positioning two thermoplastic sub-structures with webs and flanges, compressing them together, and welding the webs to create a unified structure without the need for radius fillers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If radius fillers are used to fill void spaces in conventional fabrication techniques, then the void spaces can be filled, but the fabrication process becomes time-consuming and expensive
Solution Approach 1:
The invention extracts and eliminates the radius filler component from the fabrication process. By designing sub-structures with complementary geometries that directly form the complete cross-sectional shape when joined, the patent removes the need for separate radius filler fabrication and installation steps, thereby reducing fabrication time and complexity.
Solution Approach 2:
The invention applies preliminary action by pre-forming the sub-structures with precisely engineered geometries that anticipate the final shape requirements. The transition regions are pre-designed to match complementary void spaces, so that when sub-structures are joined, the complete cross-sectional shape is achieved without requiring subsequent filler application.
2Manufacturing precision
If radius fillers are used to fill void spaces, then void spaces can be filled, but it is challenging to match the shape and mechanical properties precisely
Solution Approach 1:
The invention applies local quality by designing each sub-structure with specific geometric features tailored to its location. The transition regions of first and second sub-structures are engineered with complementary shapes that locally match the void spaces they will occupy, ensuring precise shape matching without requiring complex filler fabrication.
Solution Approach 2:
The invention merges the function of the radius filler into the sub-structures themselves. By integrating the shape-defining features directly into the first and second sub-structures' transition regions, the patent combines multiple functions (structural support and shape formation) into unified components, eliminating the need for separate filler elements.
3Manufacturing precision
If radius fillers are fabricated to match void spaces, then shape matching can be achieved, but fabrication becomes expensive
Solution Approach 1:
The invention extracts the costly radius filler fabrication step from the manufacturing process. By designing sub-structures that self-form the complete cross-sectional shape through their complementary geometries, the patent eliminates the need for expensive, precision-matched filler fabrication while maintaining shape accuracy.
Solution Approach 2:
The invention replaces expensive, custom-fabricated radius fillers with simpler, more economical sub-structure designs. The first and second sub-structures are fabricated as primary load-bearing components with integrated shape-defining features, using standard composite manufacturing processes rather than specialized filler fabrication.
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 allows for the efficient production of FRTCSMs with precise shape and mechanical properties, eliminating the need for costly radius fillers and enabling the creation of complex structural forms, such as aircraft components.
Implementation Method 1
welding the first web and the second web to one another to at least partially define the FRTCSM
Data Source
AI summary
Fiber-reinforced thermoplastic composite structural members (FRTCSM), aircraft including the same, and related methods are disclosed herein. The FRTCSMs include a first thermoplastic sub-structure that includes a first web, a first flange that extends away from the first web, and a first transition region between the first flange and the first web. The FRTCSMs also include a second thermoplastic sub-structure that includes a second web, a second flange that extends away from the second web, and a second transition region between the second flange and the second web. The first web is welded to the second web. The aircraft include at least one FRTCSM. The methods include positioning the first thermoplastic sub-structure and the second thermoplastic sub-structure such that the first web faces the second web, compressing the first web and the second web together, and welding the first web and the second web to one another.