Induction welding using a heat sink and/or cooling

Patent metadata

Field	Value
Publication number	US-11364688-B2
Application number	US-201916532941-A
Country	US
Kind code	B2
Filing date	Aug 6, 2019
Priority date	Aug 6, 2019
Publication date	Jun 21, 2022
Grant date	Jun 21, 2022

Abstract

A method of induction welding a first thermoplastic composite (TPC) to a second thermoplastic composite (TPC) includes inductively heating a weld interface area between the first TPC and the second TPC, and cooling a surface of the first TPC opposite the weld interface area while inductively heating the weld interface area.

First claim

The following is claimed:

1. A method of induction welding a first thermoplastic composite (TPC) to a second thermoplastic composite (TPC), the method comprising:
flexing a heat sink during placement onto a surface of the first TPC opposite a weld interface area, wherein flexing the heat sink includes flexing a flexible joint between a number of thermally conductive and electrically non-conductive tiles;
inductively heating the weld interface area between the first TPC and the second TPC;
cooling the surface of the first TPC opposite the weld interface area while inductively heating the weld interface area; and
wherein the heat sink includes fluid channels disposed within the flexible joints, and further comprising pumping a coolant through the fluid channels.

2. The method of claim 1 , wherein cooling the surface of the first TPC includes dissipating the heat on the surface of the first TPC via the heat sink.

3. The method of claim 1 , wherein cooling the surface of the first TPC includes actively cooling the surface of the first TPC with a coolant.

4. The method of claim 1 , wherein inductively heating includes moving an induction coil along a weld line.

5. The method of claim 1 , wherein the heat sink is infused with PTFE where in contact with the first TPC to act as a release film.

6. The method of claim 1 , wherein the heat sink has a thermal diffusivity of greater than about 25 mm 2 /sec.

7. The method of claim 1 , wherein the tiles are comprised of Aluminum nitride.

8. The method of claim 1 , wherein the tiles are comprised of Beryllium Oxide.

9. The method of claim 1 , wherein the flexible joint is comprised of a silicone.

10. The method of claim 1 , further comprising:
inserting the first TPC, the second TPC, and the heat sink within a vacuum bag; and
filling the vacuum bag with an inert gas.

11. The method of claim 1 , further comprising:
inserting the first TPC, the second TPC, and the heat sink within a vacuum bag; and

applying a vacuum to the vacuum bag to compress the first TPC and the second TPC together.

12. The method of claim 1 , further comprising cooling a surface of the second TPC opposite the weld interface area while inductively heating the weld interface area.

13. The method of claim 12 , further comprising flexing a second heat sink during placement onto the surface of the second TPC opposite the weld interface area.

14. The method of claim 13 , wherein cooling the surface of the second TPC includes dissipating the heat on the surface of the second TPC via the second heat sink.

15. A method of dissipating heat from a surface of a first thermoplastic composite (TPC) being inductively welded in a weld interface area to a second thermoplastic composite (TPC), the method comprising:
flexing a heat sink during placement above the weld interface area to conform to the surface of the first TPC, wherein flexing the heat sink includes flexing a flexible joint between a number of thermally conductive and electrically non-conductive tiles;
flexing a second heat sink during placement to conform to a surface of the second TPC, wherein the second heat sink is thermally conductive and electrically non-conductive;
applying inductive heat to the weld interface area between the first TPC and the second TPC;
drawing off heat via the heat sink from the surface of the first TPC; and
wherein the heat sink includes fluid channels disposed within the flexible joints, and further comprising pumping a coolant through the fluid channels.

16. The method of claim 15 , further comprising drawing off heat via the second heat sink from the surface of the second TPC.

17. The method of claim 15 , wherein flexing the heat sink includes conforming the heat sink to a contoured surface of the first TPC.

18. The method of claim 15 , wherein applying inductive heat includes moving and induction coil along a weld line.

19. The method of claim 15 , further comprising:
inserting the first TPC, the second TPC, the heat sink, and the second heat sink within a vacuum bag; and
filling the vacuum bag with an inert gas.

20. The method of claim 15 , further comprising:
inserting the first TPC, the second TPC, the heat sink, and the second heat sink within a vacuum bag; and
applying a vacuum to the vacuum bag to compress the first TPC and the second TPC together.

Assignees

• Boeing Co

Inventors

• Dichiara Robert A
• Samalot Rivera Francis J
• Burns Richard W

Classifications

• B29C66/524

  Joining profiled elements · CPC title

• F28F2280/105

  with hinged connections · CPC title

• F28F2280/10

  Movable elements, e.g. being pivotable · CPC title

• F28F2265/24

  for electrical insulation · CPC title

• F28F21/04

  of ceramic; of concrete; of natural stone · CPC title