Induction welding system

Patent metadata

Field	Value
Publication number	US-9868249-B2
Application number	US-201313942055-A
Country	US
Kind code	B2
Filing date	Jul 15, 2013
Priority date	Jul 15, 2013
Publication date	Jan 16, 2018
Grant date	Jan 16, 2018

Abstract

A method and apparatus for performing induction welding. A number of protective layers are positioned between a susceptor layer and at least one of a plurality of workpieces at a weld location. An undesired current path is prevented from forming at the weld location during induction heating of the plurality of workpieces by the number of protective layers.

First claim

What is claimed is:

1. An apparatus that comprises:
a retaining structure configured to retain a first workpiece and a second workpiece configured to be induction-welded to the first workpiece at a weld location;
a susceptor layer comprised of a number of susceptors;
a number of protective layers positioned between the susceptor layer and at least one of the first workpiece and the second workpiece at the weld location, the number of protective layers configured to be welded together and to prevent, during induction heating of the weld location, a flow of an electric current from at least one of:
a susceptor in the number of susceptors into the first workpiece;
the first workpiece to the second workpiece; and
the second workpiece to the first workpiece, at the weld location.

2. The apparatus of claim 1 , wherein the susceptor layer further comprises:
a weld layer configured to be welded to the number of protective layers, wherein the number of susceptors is a number of susceptor wires embedded in the weld layer.

3. The apparatus of claim 2 , wherein the weld layer is comprised of a thermoplastic material.

4. The apparatus of claim 2 , wherein the number of susceptor wires is a number of smart susceptor wires.

5. The apparatus of claim 1 , wherein the number of protective layers comprises: a material configured to prevent the flow of the electric current, a first protective layer positioned between the susceptor layer and the first workpiece at the weld location, and a second protective layer positioned between the susceptor layer and the second workpiece at the weld location.

6. The apparatus of claim 5 , wherein the first protective layer and the second protective layer are comprised of a number of materials configured to prevent the electric current from flowing between the susceptor layer and the first workpiece and between the susceptor layer and the second workpiece.

7. The apparatus of claim 5 , wherein the first workpiece is a skin and the second workpiece is a stiffener.

8. The apparatus of claim 5 , wherein the first workpiece is comprised of a first thermoplastic material and the second workpiece is comprised of a second thermoplastic material.

9. The apparatus of claim 8 , wherein the first thermoplastic material is a same material as the second thermoplastic material.

10. The apparatus of claim 5 , wherein the first protective layer and the second protective layer are comprised of a thermoplastic material selected from one of: a fiberglass material or a resin material.

11. The apparatus of claim 1 , wherein the susceptor layer and the number of protective layers form a weld stack-up for use in welding a first workpiece to a second workpiece at the weld location.

12. The apparatus of claim 11 , wherein the weld stack-up is configured for use within an induction welding system.

13. The apparatus of claim 1 , further comprising:
an induction heating system; and
a number of weld stack-ups, each weld stack-up in the number of weld stack-ups configured to be positioned at a corresponding weld location in the number of weld locations to prevent an undesired current path, outside a susceptor layer in the each weld stack-up respectively, between one surface of the each weld stack-up and an opposite surface in the each weld stack-up during induction heating of the each weld stack-up.

14. The apparatus of claim 13 , further comprising: a weld stack-up in the number of weld stack-ups positioned at a weld location in the number of weld locations that comprises:
a first protective layer positioned between the susceptor layer and the first workpiece at the weld location; and
a second protective layer positioned between the susceptor layer and the second workpiece at the weld location, such that each protective layer comprises a material configured to prevent the flow of the electric current.

15. An apparatus configured to weld a first workpiece to a second workpiece, such that the apparatus comprises:
a retaining structure configured to retain a first workpiece and a second workpiece configured to be induction-welded to the first workpiece at a weld location;
a susceptor layer that comprises an electrically conductive material;
a number of protective layers configured to sandwich the susceptor layer at the weld location, such that the number of protective layers comprises a material configured to inductive weld to objects and prevent a flow of an electric current, responsive to a current applied to the susceptor layer, from the first workpiece adjacent to a protective layer on one side of the susceptor layer, to the second workpiece adjacent to a protective layer on an opposite side of the susceptor layer.

16. The apparatus of claim 15 , further comprising:
a first protective layer positioned between the susceptor layer and a first workpiece in a plurality of workpieces at the weld location, wherein the first workpiece comprises a first thermoplastic material that comprises a first characteristic that prevents the flow of the electric current; and
a second protective layer positioned between the susceptor layer and a second workpiece in the plurality of workpieces at the weld location, wherein the second workpiece is comprised of a second thermoplastic material that comprises a second characteristic that prevents the flow of the electric current.

17. The apparatus of claim 16 , further comprising a susceptor level comprising a number of susceptors embedded within and configured to inductively heat at least one of: a weld layer in the susceptor layer, the first protective layer, the second protective layer, the first workpiece, and the second workpiece.

18. The apparatus of claim 17 , further comprising the number of susceptors configured to energize via a radio frequency electric current that generates an electromagnetic field of electromagnetic energy absorbed by the number of susceptors.

19. The apparatus of claim 18 , further comprising the number of susceptors configured to, responsive to an absorption of the electromagnetic energy, dissipate heat into at least one of: the weld layer in the susceptor layer, the first protective layer, the second protective layer, the first workpiece, and the second workpiece.

20. An apparatus configured for induction welding, such that the apparatus comprises;
a retaining structure configured to retain a first workpiece and a second workpiece configured to be induction-welded to the first workpiece at a weld location; and
a number of protective layers configured to sandwich a susceptor layer in a weld stack at the weld location, such that the number of protective layers comprises a material configured to be welded together and at least one of: interrupt, and prevent, a flow of electric current, responsive to current applied to the susceptor layer, between at least one of:
a surface, away from the susceptor layer, of a protective layer on one side of the susceptor layer, and a surface, away from the susceptor layer, of a protective layer on an opposite side of the susceptor layer; and
a susceptor in the susceptor layer and at least one of:
the surface, away from the susceptor layer, of the protective layer on the one side of the susceptor layer; and
the surface, away from the susceptor layer, of the protective layer on the opposite side of the susceptor layer, such that the susceptor layer comprises a number of susceptors configured to be energized and produce heat to a designated Curie temperature.

Assignees

• Boeing Co

Inventors

• Matsen Marc Rollo
• Miller Robert James
• Dykstra William C

Classifications

• B29C66/73921

  characterised by the materials of both parts being thermoplastics · CPC title

• B29K2909/02

  Ceramics · CPC title

• B29C66/131

  Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area · CPC title

• B29C66/474

  said single elements being substantially non-flat · CPC title

• B29L2031/3076

  Aircrafts (blades, propellers B29L2031/08) · CPC title