Welding method

Patent metadata

Field	Value
Publication number	US-12103243-B2
Application number	US-202117542893-A
Country	US
Kind code	B2
Filing date	Dec 6, 2021
Priority date	May 13, 2021
Publication date	Oct 1, 2024
Grant date	Oct 1, 2024

Abstract

Provided is a welding method including: a sheet disposition process of disposing a first and a second protection sheet such that the first and the second protection sheet come into contact with a first and a second composite material and disposing an energization sheet such that the energization sheet comes into contact with the first and the second protection sheet; and a welding process of applying a voltage to a pair of electrode portions disposed at the energization sheet and welding the first and the second composite material, the energization sheet contains the carbon fiber base material oriented in a first predetermined direction connecting the pair of electrode portions, and the first and the second protection sheet contain the carbon fiber base material oriented in a second predetermined direction that substantially perpendicularly intersects the first predetermined direction.

First claim

What is claimed is:

1. A welding method of welding a first composite material and a second composite material, each of which contains a carbon fiber base material and a thermoplastic resin, the method comprising:
a sheet disposition process of disposing a first protection sheet such that the first protection sheet comes into contact with a first bonding surface of the first composite material, disposing a second protection sheet such that the second protection sheet comes into contact with a second bonding surface of the second composite material, and disposing an energization sheet such that the energization sheet comes into contact with the first protection sheet and the second protection sheet;
an electrode disposition process of disposing a pair of electrode portions such that the electrode portions come into contact with a pair of end portions of the energization sheet; and
a welding process of applying a voltage to the pair of electrode portions and welding the first composite material and the second composite material,
wherein each of the first protection sheet, the second protection sheet, and the energization sheet contains the carbon fiber base material oriented unidirectionally and the thermoplastic resin,
the energization sheet contains only the carbon fiber base material oriented in a first predetermined direction connecting the pair of electrode portions,
the first protection sheet and the second protection sheet contain only the carbon fiber base material oriented in a second predetermined direction that substantially perpendicularly intersects the first predetermined direction,
the first protection sheet is disposed to be in direct contact with a first surface of the energization sheet, and
the second protection sheet is disposed to be in direct contact with a second surface of the energization sheet,
in the sheet deposition process, the first composite material is installed above the first protection sheet after bonding the first protection sheet, the second protection sheet, and the energization sheet to the second composite material by heating a part or all of the first protection sheet, the second protection sheet, and the energization sheet and heating the matrix resin contained therein to a temperature that is equal to or greater than the melting point.

2. The welding method according to claim 1 , further comprising:
a pressurization process of pressurizing the first composite material and the second composite material in a direction in which the first bonding surface and the second bonding surface are caused to approach each other,
wherein in the welding process, the voltage is applied to the pair of electrode portions in a state in which the first composite material and the second composite material are pressurized in the pressurization process, and the first composite material and the second composite material are thereby welded.

3. The welding method according to claim 1 , wherein a first angle formed by the second predetermined direction with respect to the first predetermined direction is equal to or greater than 87 degrees and equal to or less than 93 degrees.

4. The welding method according to claim 3 ,
wherein the first composite material and the second composite material are members extending in the second predetermined direction, and
a second angle formed by a first orientation direction of the carbon fiber base material disposed on the first bonding surface with respect to the first predetermined direction and a third angle formed by a second orientation direction of the carbon fiber base material disposed on the second bonding surface with respect to the first predetermined direction are greater than zero and less than the first angle.

5. The welding method according to claim 1 ,
wherein each of the first composite material and the second composite material is formed by laminating a plurality of sheet materials containing the carbon fiber base material and the thermoplastic resin, and
each of the first protection sheet, the second protection sheet, and the energization sheet is formed of a single sheet material containing the carbon fiber base material and the thermoplastic resin.

Assignees

• Mitsubishi Heavy Ind Ltd

Inventors

• Tanaka Daisuke
• Otobe Shogo
• Tsumura Yoichiro

Classifications

• B29C70/06

  Fibrous reinforcements only · CPC title

• B29C66/919

  characterised by specific temperature, heat or thermal flux values or ranges (specific electrical resistance values B29C66/81262) · CPC title

• B29C66/71

  characterised by the composition of the plastics material of the parts to be joined (welding bar compositions B29C65/125) · CPC title

• B29C66/43

  Joining a relatively small portion of the surface of said articles (B29C66/45 takes precedence) · CPC title

• B29C65/3468

  characterised by the means for supplying heat to said heated elements which remain in the join, e.g. special electrical connectors of windings (B29C65/3668 takes precedence) · CPC title