Patent Application
20230382060
Embodiments of the present invention relate to an apparatus and method for induction fusing of thermoplastic composite materials.
Thermoplastic composite materials have long been of interest to aerostructures manufacturers because they offer certain potential advantages when compared to more conventional thermoset composite materials. Unlike thermosets, thermoplastic materials can be re-melted after solidification, thus facilitating recycling of both manufacturing waste and completed aerostructures at the end of their life cycles. This capability can reduce environmental externalities relating to both disposal of waste and manufacture of new material. The same re-meltable characteristic of thermoplastics that facilitates recycling also enables thermoplastic components to be joined into assemblies by fusing (welding) rather than relying exclusively on fasteners, thereby potentially reducing an assembly's weight as well as simplifying its manufacture.
Unfortunately, existing thermoplastic welding processes and equipment have drawbacks that have limited the adoption of thermoplastics in the aerospace industry. Some known welding techniques employ metallic mesh susceptors that remain embedded in the weld line after the constituent components are joined. This adds weight and reduces weld strength and reliability. Other known welding techniques melt the components to be welded through their full thicknesses, necessitating complex tooling or pressure application means to prevent deconsolidation, and reducing process robustness. Susceptorless induction welding is perhaps the most promising technology under development due to its ability to directly heat conductive fibers such as carbon fibers present in composite laminates, without leaving a susceptor in the weld line.
Although a rapidly alternating magnetic field emanating from an induction coil can directly heat conductive fibers in all layers of a thermoplastic composite laminate, even those layers spaced further apart from the induction coil, different layers will receive different amounts of energy. The strength of a magnetic field decreases with distance in accordance with the inverse square law. Therefore, surface layers positioned nearer the induction coil are heated much more strongly than layers further away. To avoid overheating of layers near the surface, causing the thermoplastic material to degrade, and to prevent softening of layers within the laminate, causing delamination, it has been proposed to actively cool the exposed surface of a thermoplastic workpiece nearest the induction coil while simultaneously applying induction energy to the workpiece.
This approach is described in Italian Patent ITTO20130367A1 (“Pappada”) and it represented a significant advance in the art of induction welding when disclosed. It has been demonstrated that the Pappada approach can achieve a more uniform through-thickness heat distribution than prior induction heating approaches. However, important limitations have remained, preventing widespread adoption of susceptorless thermoplastic induction welding. In particular, the single large roller employed by Pappada to apply clamping force to the workpieces to be welded is spaced apart from the induction heating coil. Thus, the Pappada device cannot apply clamping force at the same location at which induction heat is applied, and cannot maintain clamping pressure over any significant area at once. The result is an inability to maintain pressure at any given location over time without sacrificing process speed. Furthermore, Pappada's air impingement cooling method operates in free air, so its ability to transfer heat out of the workpieces is limited by boundary layer phenomena.
A significant advance over the Pappada invention has recently been disclosed in U.S. patent application Ser. No. 17/207,647 (“Seneviratne”). The Seneviratne invention provides a plurality of small rollers to apply pressure to the workpieces in place of the single roller of Pappada, thus enabling clamping pressure to be maintained over a greater area and for a greater period of time for a given process speed. The Seneviratne invention also enables clamping pressure to be applied to a workpiece at the same location as the induction energy is introduced, and at the same time, which was not possible with the Pappada device. However, although clamping pressure is applied more evenly over a larger area by the Seneviratne invention, the pressure is still not entirely uniform due to the discrete contact locations inherent in a roller based design. The Seneviratne invention is also limited by its reliance on conduction to transfer heat out of the workpiece and into the rollers. The interface area between a roller and any flat workpiece is infinitesimally small, limiting the potential for heat transfer even where multiple rollers are employed. This heat transfer limitation is exacerbated by the need for the rollers to be made of a material with a low electrical conductivity (to avoid interaction with the induction field), as most materials with low electrical conductivity have a correspondingly low thermal conductivity. In addition, the rollers, being closely spaced as they must be to apply a relatively uniform pressure, form a barrier, blocking airflow that might otherwise be employed to supplement the cooling of the workpiece in the region of the induction coil. Finally, the large standoff distance resulting from positioning the induction coil on the opposite side of the rollers from the workpiece limits the precision with which the boundary of the heated zone of the workpiece can be controlled, and necessitates the generation of a more powerful induction field than would otherwise be required. Such a powerful induction field may heat any highly conductive (e.g., metallic) components of the equipment, and especially any ferromagnetic components, even when they may be positioned a significant distance away, complicating the design of equipment used to implement the Seneviratne invention. Furthermore, the higher energy expenditure required to generate a more powerful induction field is inconsistent with the sustainability goals of the aerospace industry.
The present invention overcomes the above-described limitations of the prior art and provides a distinct advance in the art of thermoplastic composite manufacture. It is an object of the present invention to provide a thermoplastic induction fusing apparatus capable of applying a more uniform pressure to the fusing area than prior art thermoplastic induction fusing devices. It is a further object of the present invention to provide a thermoplastic induction fusing apparatus capable of accommodating workpiece contour variations without adjustment. It is a further object of the present invention to provide a thermoplastic induction fusing apparatus with enhanced ability to transfer heat away from the workpiece. It is a further object of the present invention to provide a method by which thermoplastic workpieces may be fused together by means of induction.
An apparatus is disclosed herein for fusing a far surface of a near thermoplastic workpiece to a near surface of a far thermoplastic workpiece. The apparatus comprises an induction coil configured to heat a fusing area of the near workpiece and the far workpiece. The apparatus further comprises an air cushion block configured to emit compressed air against a near surface of the near thermoplastic workpiece in the fusing area, urging the near thermoplastic workpiece toward the far thermoplastic workpiece.
A system is disclosed herein for fusing a thermoplastic composite material. The system comprises an induction fusing apparatus. The system further comprises a pressurized fluid disposed between the induction fusing apparatus and the thermoplastic composite material. The system further comprises an assembly tool configured to react force applied by the pressurized fluid to the thermoplastic composite material. The system further comprises a manipulator configured to move the induction fusing apparatus along a surface of the thermoplastic composite material.
A method is disclosed herein for applying heat and pressure to a work area of a workpiece. The method comprises exposing the workpiece to an alternating magnetic field in the work area. The method further comprises positioning a surface of a reaction block proximate to, but spaced apart from, a surface of the workpiece in the work area. The method further comprises introducing a pressurized fluid into the gap between the surface of the reaction block and the surface of the workpiece.
This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Other aspects and advantages of the present invention will be apparent from the following detailed description of the preferred embodiments and the accompanying drawing figures.
Embodiments of the present invention are described in detail below with reference to the attached drawing figures, wherein:
The following detailed description makes reference to accompanying drawings that illustrate specific embodiments of the present invention. Separate references to “an embodiment” or “one embodiment” do not necessarily refer to the same embodiment, though they may. The specific embodiments illustrated and/or described in detail in this disclosure are included to enable those skilled in the art to practice the invention. Other embodiments and variations will be apparent to those skilled in the art and may be substituted without departing from the scope of the present invention. Therefore, the detailed description that follows should not be construed in a limiting sense.
Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, a system 100 in accordance with an embodiment of the present invention is illustrated in
Referring now to
The secondary frame 208 may be mechanically coupled to the air cushion block 220, which may also be described as a “reaction block.” The air cushion block 220 is described in more detail below and in the various figures. Primary air line 216 is in fluid communication via a manifold (not shown) with secondary air lines 218, which are in turn in fluid communication with the air cushion block 220. The induction power supply 212 may be electrically coupled to the induction coil 214 as illustrated in
Referring now to
The air between the air cushion block 220 and the workpiece 102 may serve to provide a uniform pressure and maintain intimate contact between the workpiece 102 and the workpiece 106 when the fusing area is heated, and may also prevent internal deconsolidation of the workpieces 102, 106. The air flowing between the air cushion block 220 and the workpiece 102 may also serve to simultaneously cool the workpiece 102 as pressure is applied. Cooling of the surface of workpiece 102 is important because workpiece 102 may heat more rapidly than workpiece 106 when exposed to a magnetic field emanating from induction coil 214, due to the closer proximity of workpiece 102 to induction coil 214. The gap between the air cushion block 220 and the workpiece 102 may be relatively small, which may advantageously maintain the air in direct contact with the workpiece 102 as it migrates to the periphery of the air cushion block 220, preventing the formation of a boundary layer on the workpiece 102, and thereby enhancing heat transfer from the workpiece 102 into the air layer between the air cushion block 220 and the workpiece 102. Specifically, the gap between the air cushion block 220 and the workpiece 102 may be less than 3 mm, less than 2 mm, less than 1 mm, or less than 0.5 mm.
Importantly, the air flowing between the air cushion block 220 and the workpiece 102 may be disposed between the induction coil 214 and workpiece 102, thus enabling cooling at the same location of the workpiece 102 that is simultaneously heated by the induction coil 214. This arrangement is particularly advantageous when thermoplastic welding is performed with no susceptor layer at the weld interface, as in such case effective cooling of the surface of the workpiece 102 is critical. Susceptorless induction heating of a workpiece 102 tends to result in heating and softening of the workpiece 102 through its full thickness, not only at the weld interface. Therefore, a workpiece 102 heated by susceptorless induction heating may lack rigidity in the vicinity of heat application, and the workpiece 102 may thus be incapable of carrying clamping force from a remote location to the location of heat application. Accordingly, it may be essential to apply pressure directly at the location to which heat is applied and at the time that heat is applied. The configuration of the present invention addresses this need while also enabling the induction coil 214 to be positioned in close proximity to the workpiece 102, minimizing the magnetic field strength required to heat the workpieces 102, 106.
The air flowing between the air cushion block 220 and the workpiece 102 may also cool the surface of the air cushion block 220, which might otherwise accumulate heat from the workpiece 102 via radiation. This active cooling effect may advantageously allow the air cushion block 220 to be made of a material such as plastic or silicone rubber that is not capable of operating at the working temperature of the workpiece 102.
Consolidation pressure may only be required in melted or softened areas of the workpiece 102. Therefore, the area of the workpiece 102 over which the pressurized air of the present invention acts may be largely limited to that area of the workpiece 102 that is melted or softened by the induction coil 214. Applying pressure to a larger area outside the melted or softened area may generate an unnecessarily large force that must be reacted through the manipulator 202, and may reduce the amount of pressure that can be generated in the critical melted or softened area. In contrast to a conventional “air caster,” wherein the aim is to apply a force (e.g., to lift an object), and wherein the force generated can be increased by increasing the area over which the available air pressure acts, it is the aim of the present invention to apply a sufficient pressure to a softened or molten area of the workpiece 102 to maintain consolidation without regard to the total force produced. Thus, while it is typical in the case of an “air caster” to maximize the area to which pressure is applied while keeping the pressure itself low, such a configuration would not provide adequate consolidation pressure to a molten or softened area of a thermoplastic composite workpiece 102. In the case of the present invention, wherein the area acted upon may be confined to a molten or softened area of the workpiece 102, the pressure of the pressurized air between the air cushion block 220 and the workpiece 102 may be significantly higher. Specifically, the pressure of the pressurized air between the air cushion block 220 and the workpiece 102 may be at least 2 bar, at least 3 bar, at least 5 bar, at least 7 bar, at least 9 bar, or at least 11 bar.
Referring now to
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It should be noted that some features of the air cushion block 220 are omitted from the depictions in
Referring now to
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Although the present invention is described herein primarily in the context of thermoplastic “welding,” which is usually thought of as the joining of two pre-consolidated laminates, those skilled in the art will recognize that the present invention is also applicable to lamination, i.e., the process of fusing a single new ply of thermoplastic composite material to a previously deposited ply of thermoplastic composite material. Referring to
At least a portion of the steps of a method 300 for manufacturing a thermoplastic composite component using the system 100 and the apparatus 200 in accordance with various embodiments of the present invention are listed in
The method 300 may comprise a step of exposing a workpiece to an alternating magnetic field in a work area of the workpiece as depicted in flow chart block 310.
The method 300 may comprise a step of positioning a surface of a reaction block 220 proximate to, but spaced apart from, a surface of the workpiece 102 in the work area as depicted in flow chart block 320. The work area of the workpiece 102 described in flow chart blocks 310 and 320 may be a first work area of a plurality of work areas of the workpiece 102.
The method 300 may comprise a step of introducing a pressurized fluid into the gap between the surface of the reaction block 220 and the surface of the workpiece 102 as depicted in flow chart block 330. The step depicted in flow chart block 330 may be performed in parallel with the step depicted in flow chart block 310. Thus, pressure may be applied to a location of the workpiece 102 at the same time heat is applied to such location.
The method 300 may comprise a step of moving the reaction block over the surface of the workpiece to a second work area.
The method 300 may comprise a step of exposing the workpiece to an alternating magnetic field at the second work area.
The method 300 may comprise a step of maintaining pressurized fluid in the gap between the surface of the reaction block 220 and the surface of the workpiece 102 as the reaction block 220 is moved from the first work area of the workpiece 102 to the second work area of the workpiece 102, and as the second work area of the workpiece 102 is exposed to an alternating magnetic field.
Although the invention has been described with reference to the preferred embodiments illustrated in the attached drawing figures, it is noted that equivalents may be employed and substitutions made herein without departing from the scope of the invention as recited in the claims.
| Number | Date | Country | |
|---|---|---|---|
| 63345086 | May 2022 | US |
