Wire Mesh Resistive Welding for 3D Thermoplastic Composite Joints
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional resistive implant welding methods fail to effectively weld complex three-dimensional thermoplastic composite parts with sharp angles due to limitations in bending wire mesh, leading to reduced functionality and weld failure.
Innovation Solution
The method involves stacking wire mesh strips at intersection points to create separate circuits, allowing for larger bend angles and ensuring proper electrical contact, enabling the welding of parts with angles exceeding 45 degrees by using a probe to energize each circuit individually with unique processing parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If wire mesh is bent to conform to complex three-dimensional surfaces with sharp angles, then the mesh can be applied to the surface, but the mesh becomes contorted and functionality is reduced or causes failure
Solution Approach 1:
The wire mesh is divided into multiple separate strips that can be independently positioned and stacked at intersection points. This segmentation allows each strip to maintain its structural integrity and electrical conductivity while conforming to complex three-dimensional surfaces with sharp angles, preventing the contortion and failure that occurs when a single continuous mesh is bent excessively.
2Ease of manufacture
If wire mesh is used for resistive implant welding, then welding of thermoplastic composites is achieved, but current shunting occurs in complex geometries leading to weld failure
Solution Approach 1:
The wire mesh is segmented into multiple strips with discrete electrical circuits. Each strip forms a separate circuit path that can be independently controlled, preventing current shunting between adjacent mesh elements that occurs in complex geometries. This segmentation ensures reliable current flow through the intended path for consistent welding results.
Solution Approach 2:
Different regions of the wire mesh are designed with locally optimized properties. The mesh strips are positioned and stacked at specific intersection points to create tailored circuit paths that adapt to the local geometry of the part being welded. This local optimization ensures proper current distribution and prevents shunting in complex areas while maintaining welding capability throughout.
3Device complexity
If single circuit mesh is used, then simple welding paths are achieved, but complex three-dimensional weld joints cannot be properly welded
Solution Approach 1:
The welding system uses multiple discrete wire mesh strips that can be stacked at intersection points to create complex circuit paths. Each strip maintains a relatively simple individual structure, but their combination enables welding of complex three-dimensional joints. This segmented approach achieves versatility without requiring each individual component to be overly complex.
Solution Approach 2:
The solution transitions from a two-dimensional single circuit mesh to a three-dimensional stacked mesh configuration. By stacking mesh strips at intersection points, the system creates multiple circuit layers that can navigate complex three-dimensional geometries, enabling weld joints in multiple directions and angles that cannot be achieved with a single planar circuit.
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 flexible welding of complex three-dimensional parts with increased weld strength and quality, tailored to the specific design, by preventing current shunting and ensuring effective molten material flow through the mesh weave.
Implementation Method 1
resistive implant welding
Implementation Method 2
stacking wire mesh strips at intersection points to create separate circuits
Data Source
Figure 1~2
Figure 3
Figure 4~7
AI summary
A method of resistive implant welding thermoplastic composites. At least two sections of a component formed with weldable thermoplastic material are provided. The two sections of the component each have a welding surface along which the component is welded together. The welding surface includes a first surface adjoining a second surface at an angle exceeding about 30 degrees or another three dimensional shape. A first wire mesh conductor material is positioned between the welding surface of the at least two sections along the first surface. A second wire mesh conductor material is positioned between the welding surface of the at least two sections along the second surface in an overlapping manner at the angled connection. An electric current is applied to the conductors causing the conductors to heat up and melt the at least two sections of the component together.