Patent Application
20230382059
The present disclosure relates to assemblies, systems and characterization methods of welded joints for thermoplastic components and, more particularly, to assemblies, systems and characterization methods of welded joints for thermoplastic components (e.g., thermoplastic-based fiber-reinforced composites) utilizing visualization agents (e.g., pigments and/or fluorescent agents).
In general, the welding of thermoplastic components and/or thermoplastic-based fiber-reinforced composites can provide for efficient joining of separate thermoplastic parts with benefits of cost/labor reduction, technological convenience and/or opportunities to design and optimize complex-shape structures. However, in contrast with more traditional adhesion-based bonding of thermoplastic materials or composites, welding-based joining can be associated with through-thickness physical processes, resulting in complex interconnection areas between welded parts. Conventional practice provides almost non-existent or very limited visualization of the welded interconnection areas for thermoplastic components/composites.
The present disclosure provides assemblies for characterization of welded joints for thermoplastic components, and improved systems/methods of characterization of welded joints for thermoplastic components. More particularly, the present disclosure provides embodiments that may result in improved assemblies, systems and methods of characterization of welded joints for thermoplastic components (e.g., thermoplastic-based fiber-reinforced composites) utilizing visualization agents (e.g., pigments and/or fluorescent agents).
The present disclosure provides for a thermoplastic component assembly including a first thermoplastic component comprising a first thermoplastic polymer material, the first thermoplastic polymer material comprising a first visualization agent; and a second thermoplastic component comprising a second thermoplastic polymer material; wherein the first visualization agent is configured to operate as visual contrast under lighting conditions to identify a boundary or interconnection area between the first thermoplastic component welded to the second thermoplastic component.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, the first thermoplastic component and/or the second thermoplastic component is a thermoplastic-based composite component, the thermoplastic-based composite component comprising reinforcing fibers.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, the first visualization agent comprises a first pigment or a first fluorescent agent.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, the boundary or interconnection area is a distinct monotonic, a distinct stochastic or a stochastic blurred boundary or interconnection area.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, the second thermoplastic polymer material comprises a second visualization agent; and the second visualization agent is configured to operate as visual contrast under lighting conditions to identify the boundary or interconnection area between the first thermoplastic component welded to the second thermoplastic component.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, the first thermoplastic component comprises a first thermoplastic layer of the first thermoplastic polymer material and a second thermoplastic layer of the first thermoplastic polymer material; and the second thermoplastic layer of the first thermoplastic polymer material comprises a second visualization agent.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, the first thermoplastic component comprises a third thermoplastic layer of the first thermoplastic polymer material; and the third thermoplastic layer comprises a third visualization agent.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, the thickness of the first thermoplastic layer is substantially uniform with the thickness of the second thermoplastic layer, and the thickness of the first thermoplastic layer is substantially uniform with the thickness of the third thermoplastic layer.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, the thickness of the first thermoplastic layer is less than the thickness of the second thermoplastic layer, and the thickness of the second thermoplastic layer is less than the thickness of the third thermoplastic layer.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, the first thermoplastic component comprises a fourth thermoplastic layer of the first thermoplastic polymer material; and the fourth thermoplastic layer is free of a visualization agent.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, the second thermoplastic component comprises a first thermoplastic layer of the second thermoplastic polymer material and a second thermoplastic layer of the second thermoplastic polymer material; and the first thermoplastic layer of the second thermoplastic polymer material comprises a third visualization agent, and the second thermoplastic layer of the second thermoplastic polymer material comprises a fourth visualization agent.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, the first thermoplastic component comprises a plurality of first thermoplastic layers of the first thermoplastic polymer material with the first visualization agent; and the first thermoplastic component comprises a plurality of second thermoplastic layers of the first thermoplastic polymer material with a second visualization agent.
The present disclosure provides for a characterization method including providing a first thermoplastic component comprising a first thermoplastic polymer material, the first thermoplastic polymer material comprising a first visualization agent; and providing a second thermoplastic component comprising a second thermoplastic polymer material; welding the first thermoplastic component to the second thermoplastic component; and subjecting the welded first and second thermoplastic components to a light source, with the first visualization agent operating as visual contrast under the light source to identify a boundary or interconnection area between the first thermoplastic component welded to the second thermoplastic component.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, the first thermoplastic component or the second thermoplastic component is a thermoplastic-based composite component, the thermoplastic-based composite component comprising reinforcing fibers.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, the first visualization agent comprises a first pigment or a first fluorescent agent.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, the boundary or interconnection area is a distinct monotonic, a distinct stochastic or a stochastic blurred boundary or interconnection area.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, the second thermoplastic polymer material comprises a second visualization agent; and wherein after subjecting the welded first and second thermoplastic components to the light source, the second visualization agent operates as visual contrast under the light source to identify the boundary or interconnection area between the first thermoplastic component welded to the second thermoplastic component.
The present disclosure provides for a characterization method including providing a first thermoplastic component comprising a first thermoplastic polymer material, the first thermoplastic polymer material comprising a first visualization agent; providing a second thermoplastic component comprising a second thermoplastic polymer material; welding the first thermoplastic component to the second thermoplastic component; removing a first excess portion of the first and second thermoplastic components along a first removal surface; and subjecting the welded first and second thermoplastic components along the first removal surface to a light source, with the first visualization agent operating as visual contrast under the light source to identify a boundary or interconnection area between the first thermoplastic component welded to the second thermoplastic component.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, further including removing a second excess portion of the first and second thermoplastic components along a second removal surface; and subjecting the welded first and second thermoplastic components along the second removal surface to the light source, with the first visualization agent operating as visual contrast under the light source to identify the boundary or interconnection area between the first thermoplastic component welded to the second thermoplastic component.
In addition to one or more of the features described, or as an alternative to any of the foregoing embodiments, the first thermoplastic component or the second thermoplastic component is a thermoplastic-based composite component, the thermoplastic-based composite component comprising reinforcing fibers.
The above described and other features are exemplified by the following figures and detailed description.
Any combination or permutation of embodiments is envisioned. Additional features, functions and applications of the disclosed assemblies, systems and methods of the present disclosure will be apparent from the description which follows, particularly when read in conjunction with the appended figures. All references listed in this disclosure are hereby incorporated by reference in their entireties.
The following figures are example embodiments wherein the like elements are numbered alike.
Features and aspects of embodiments are described below with reference to the accompanying drawings, in which elements are not necessarily depicted to scale.
Example embodiments of the present disclosure are further described with reference to the appended figures. It is to be noted that the various features, steps, and combinations of features/steps described below and illustrated in the figures can be arranged and organized differently to result in embodiments which are still within the scope of the present disclosure. To assist those of ordinary skill in the art in making and using the disclosed assemblies, systems and methods, reference is made to the appended figures, wherein:
The example embodiments disclosed herein are illustrative of assemblies for characterization of welded joints for thermoplastic components, and systems of the present disclosure and methods/techniques thereof. It should be understood, however, that the disclosed embodiments are merely examples of the present disclosure, which may be embodied in various forms. Presented examples show assemblies of two thermoplastic components, however, the same embodiments can be used for assemblies comprising more than two components. Therefore, details disclosed herein with reference to example assemblies for characterization of welded joints for thermoplastic components (e.g., thermoplastic-based fiber-reinforced composites) and associated processes/techniques of fabrication/assembly and use are not to be interpreted as limiting, but merely as the basis for teaching one skilled in the art how to make and use the assemblies/systems and/or alternative assemblies/systems of the present disclosure.
The present disclosure provides assemblies, systems and characterization methods of welded joints for thermoplastic components.
More particularly, the present disclosure provides assemblies, systems and characterization methods of welded joints for thermoplastic components (e.g., thermoplastic-based fiber-reinforced composites) utilizing visualization agents (e.g., pigments and/or fluorescent agents).
As noted above, current practice provides almost no or very limited visualization of the welded interconnection areas for thermoplastic components/composites. Understanding of actual physical processes in the welded interconnection areas and quantification of actual welded patterns through advanced visualization can be important for further optimization of welded processes and their cost-efficient mechanical characterization and quality inspection. For example, understanding and characterizing these interconnection areas between welded parts can be important for the acceleration of welding-based product development, the optimization of manufacturing processes, the identification of potential risks and their mitigations, and the reduction of conservatism in composite designs. In example embodiments, the present disclosure provides for assemblies, systems and characterization methods of welded joints for thermoplastic components (e.g., thermoplastic-based fiber-reinforced composites) with enhanced visualization, sufficient for qualitative and quantitative assessment of the welded interconnected areas.
First thermoplastic component 12 and second thermoplastic component 14 each include a thermoplastic polymer material. It is noted that the thermoplastic polymer material of the first thermoplastic component 12 can be the same as or different than the thermoplastic polymer material of the second thermoplastic component 14.
In some embodiments, the first thermoplastic component 12 and/or the second thermoplastic component 14 takes the form of a thermoplastic-based fiber-reinforced composite component 12, 14, (e.g., a thermoplastic material that includes fibers, such as reinforcing carbon, glass or organic (e.g., Kevlar) fibers, any of their combinations, or the like). The reinforcing fibers can be continuous fibers, short (chopped) fibers or organized as an interwoven fabric. The reinforcement layups can include, among others, laminated designs, comprising of sets of uni-directionally-reinforced or fabric plies, or 2D or 3D woven configurations.
In contrast with conventional practice where the boundary or interconnection area between welded parts can barely be seen, the present disclosure provides that one or more visualization agents 18 (e.g., bright pigments 18 and/or fluorescent agents 18) can be added to the thermoplastic polymer material or matrix of the first thermoplastic component 12 and/or the second thermoplastic component 14 to make the boundary or interconnection area 16 between welded components 12, 14 clearly observed and assessed. It is noted that some embodiments utilize fluorescent agents 18 instead of, or in addition to, the pigments 18 to provide bright reflection under light (e.g., ultraviolet or UV light) to detect the clear boundary or interconnection area 16 between welded components 12, 14. In example embodiments, when pigments 18 are utilized as the visualization agents 18, the clear boundary or interconnection area 16 between welded components 12, 14 can be detected under normal lighting conditions (e.g., room lighting). In other embodiments, fluorescent agents 18 and/or dyes that absorb UV light (e.g., around 350 nm wavelengths) and fluoresce in the visible spectrum can be utilized to detect the clear boundary or interconnection area 16 between welded components 12, 14.
As shown in
It is noted that through-thickness cross-sectional side views or generated clear through-thickness views of assembly 10 as shown in
For example and as shown in
As shown in
In certain embodiments, the thickness or height of each layer 12A, 12B, 12C is substantially uniform or similar, although the present disclosure is not limited thereto.
In some embodiments, assembly 10 can include a plurality of first layers 12A with first visualization agent 18A (e.g., two first layers 12A; three first layers 12A; a plurality of first layers 12A; etc.), with each additional first layer 12A stacked on top of a respective first layer 12A.
Similarly, assembly 10 can include a plurality of second layers 12B with second visualization agent 18B (e.g., two second layers 12B; three second layers 12B; a plurality of second layers 12B; etc.), with each additional second layer 12B stacked on top of a respective second layer 12B.
Likewise, assembly 10 can include a plurality of third layers 12C with third visualization agent 18C (e.g., two third layers 12C; three third layers 12C; a plurality of third layers 12C; etc.), with each additional third layer 12C stacked on top of a respective third layer 12C.
In other embodiments and as shown in
As similarly described with respect to
Moreover, the first thermoplastic layer 14A of component 14 includes a fourth visualization agent 18D (e.g., fourth bright pigment 18D and/or fourth fluorescent agent 18D) mixed with the polymer of the second thermoplastic component 14, and the second thermoplastic layer 14B of component 14 includes a fifth visualization agent 18E (e.g., fifth bright pigment 18E and/or fifth fluorescent agent 18E) mixed with the polymer of the second thermoplastic component 14, and the third thermoplastic layer 14C of component 14 includes a sixth visualization agent 18F (e.g., sixth bright pigment 18F and/or sixth fluorescent agent 18F) mixed with the polymer of the second thermoplastic component 14. In certain embodiments, the fourth visualization agent 18D, the fifth visualization agent 18E and the sixth visualization agent 18F are all different from one another, although the present disclosure is not limited thereto.
In certain embodiments, the thickness or height of each layer 14A, 14B, 14C is substantially uniform or similar, although the present disclosure is not limited thereto.
In some embodiments, assembly 10 can include a plurality of first layers 14A with fourth visualization agent 18D (e.g., two first layers 14A; three first layers 14A; a plurality of first layers 14A; etc.), with each additional first layer 14A stacked on top of a respective first layer 14A.
Similarly, assembly 10 can include a plurality of second layers 14B with fifth visualization agent 18E (e.g., two second layers 14B; three second layers 14B; a plurality of second layers 14B; etc.), with each additional second layer 14B stacked on top of a respective second layer 14B.
Likewise, assembly 10 can include a plurality of third layers 14C with sixth visualization agent 18F (e.g., two third layers 14C; three third layers 14C; a plurality of third layers 14C; etc.), with each additional third layer 14C stacked on top of a respective third layer 14C.
As shown in
As similarly described above, the first thermoplastic layer 12A includes a first visualization agent 18A, the second thermoplastic layer 12B includes a second visualization agent 18B, the third thermoplastic layer 12C includes a third visualization agent 18C, and the fourth thermoplastic layer 12D includes a fourth visualization agent 18D (e.g., fourth bright pigment 18D and/or fourth fluorescent agent 18D) mixed with the polymer of the first thermoplastic component 12, to visually emphasize the boundary or interconnection area 16 between welded components 12, 14 (e.g., for improved visual contrast of the boundary or interconnection area 16 between welded components 12, 14). In certain embodiments, the first visualization agent 18A, the second visualization agent 18B, the third visualization agent 18C, and the fourth visualization agent 18D are all different from one another, although the present disclosure is not limited thereto.
In certain embodiments, the thickness or height of each layer 12A, 12B, 12C, 12D can vary from one another, although the present disclosure is not limited thereto.
For example and as shown in
As similarly described above, assembly 10 can include a plurality of first layers 12A with first visualization agent 18A, and/or a plurality of second layers 12B with second visualization agent 18B, and/or a plurality of third layers 12C with third visualization agent 18C, and/or a plurality of third layers 12C with third visualization agent 18C.
As shown in
After welding first thermoplastic component 12 to second thermoplastic component 14, the first excess portion 20 can be cut away or removed from assembly 10 along surface A-A of
The analysis as provided by the removal of portions 20, 20A allows for accelerated development of welding technology, understanding of potential risks associated with thermoplastic welding, and overall design optimization of welded assembly 10.
There are many benefits of the assemblies, systems and methods of the present disclosure, including, without limitation: acceleration of thermoplastic product development, using welding process; clear qualitative and quantitative metrics of welding process for benchmarking and optimization; and/or the opportunity to utilize with both aircraft and non-aircraft applications/components.
While particular embodiments have been described, alternatives, modifications, variations, improvements, and substantial equivalents that are or may be presently unforeseen may arise to applicants or others skilled in the art. Accordingly, the appended claims as filed and as they may be amended are intended to embrace all such alternatives, modifications variations, improvements, and substantial equivalents.
The ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other (e.g., ranges of “up to 25 wt. %, or, more specifically, 5 wt. % to 20 wt. %”, is inclusive of the endpoints and all intermediate values of the ranges of “5 wt. % to 25 wt. %,” etc.). “Combinations” is inclusive of blends, mixtures, reaction products, and the like. The terms “first,” “second,” and the like, do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The terms “a” and “an” and “the” do not denote a limitation of quantity and are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. “Or” means “and/or” unless clearly stated otherwise. Reference throughout the specification to “some embodiments”, “an embodiment”, and so forth, means that a particular element described in connection with the embodiment is included in at least one embodiment described herein, and may or may not be present in other embodiments. In addition, it is to be understood that the described elements may be combined in any suitable manner in the various embodiments. A “combination thereof” is open and includes any combination comprising at least one of the listed components or properties optionally together with a like or equivalent component or property not listed.
Unless defined otherwise, technical and scientific terms used herein have the same meaning as is commonly understood by one of skill in the art to which this application belongs. All cited patents, patent applications, and other references are incorporated herein by reference in their entirety. However, if a term in the present application contradicts or conflicts with a term in the incorporated reference, the term from the present application takes precedence over the conflicting term from the incorporated reference.
Although the systems and methods of the present disclosure have been described with reference to example embodiments thereof, the present disclosure is not limited to such example embodiments and/or implementations. Rather, the systems and methods of the present disclosure are susceptible to many implementations and applications, as will be readily apparent to persons skilled in the art from the disclosure hereof. The present disclosure expressly encompasses such modifications, enhancements and/or variations of the disclosed embodiments. Since many changes could be made in the above construction and many widely different embodiments of this disclosure could be made without departing from the scope thereof, it is intended that all matter contained in the drawings and specification shall be interpreted as illustrative and not in a limiting sense. Additional modifications, changes, and substitutions are intended in the foregoing disclosure. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the disclosure.
