Rohr, Inc.

Jonathan S Huang

Michael Van Tooren

Jeffrey D Woods

Robert Lechner

Dominic J Elliott

Milan Mitrovic

Noushin Bahramshahi

Daniel O Ursenbach

Andrew Adan

Charles Novak

Fassil Ghebremichael

Jeffrey Woods

A system and method for welding thermoplastic components is provided. The system includes a component positioning system and a welding subsystem. The component positioning system includes a trailing force applicator having first and second lateral side trailing force applicators disposed on opposite lateral sides of a weld line. The welding subsystem is configured to weld the thermoplastic components together at a weld zone. The first and second lateral side trailing force applicators are laterally spaced apart from the weld zone, and at least a portion of the first and second lateral side trailing force applicators are disposed aft of the weld zone. During welding the first and second lateral side trailing force applicators and a welding subsystem probe are moved relative to the thermoplastic components, or vice versa.

Method and system for welding thermoplastic panels

An induction welding assembly and inductive welding method is disclosed. A tooling block includes a workpiece zone, a conductive heat generation and transfer member, and a heat shield, with the conductive heat generation and transfer member being disposed between the workpiece zone and the heat shield. A first workpiece and a second workpiece may be disposed within the workpiece zone such that the first workpiece is disposed between the conductive heat generation and transfer member and the second workpiece. The heat shield, conductive heat generation and transfer member, first workpiece, and second workpiece may be pressed together. An induction coil may be positioned in spaced relation to the heat shield and may be operated to heat the conductive heat generation and transfer member. Heat is conductively transferred by the conductive heat transfer member to the first workpiece to weld the first workpiece and the second workpiece together.

Inductive welding assembly and method using conductive heat transfer strip

Systems and methods for induction welding a stiffener to a thermoplastic composite structure using a removeable metal mask to reduce excess heat along the edges of the stiffener generated from an electromagnetic field of an induction welding tool.

Use of removable metal frames to control induction welding of thermoplastic composite edges

An assembly is provided for induction welding. This assembly utilizes a heat shield (e.g., a mica heat shield) with a recess. An induction welding coil may be disposed within this heat shield recess during induction welding operations. The wall thickness of the heat shield within the recess may be reduced to enhance heat transfer to a workpiece during induction welding operations. Members may engage the heat shield on opposite sides of the recess (and that have an increased wall thickness) to support both the heat shield and the workpiece during induction welding operations, during which a biasing force may be exerted on both the heat shield and workpiece.

Heat shield with coil recess for induction welding

A welding assembly is disclosed. The welding assembly includes a plurality of separately controllable actuators (e.g., pneumatic, having an axially movable ram) to press a corresponding portion of a first workpiece (e.g., a discrete flange of a first stiffener) against a second workpiece (e.g., an outer skin) for welding operations (e.g., via induction welding).

Welding assembly and method using separately actuatable rams

A method for forming a fiber-reinforced thermoplastic part may comprise the steps of locating a lightning strike protection layer on a mold surface of a mold tool, locating a thermoplastic layer over the mold tool, heating the thermoplastic layer to a pliable forming temperature, conforming the thermoplastic layer to a mold surface of the mold tool, and depositing a plurality of fiber strips over the thermoplastic layer.

Assemblies and methods for forming fiber-reinforced thermoplastic structures with lightning strike protection

A method for forming a fiber reinforced thermoplastic part may comprise the steps of locating a thermoplastic material over a mold tool, heating the thermoplastic material to a pliable forming temperature, conforming the thermoplastic material to a mold surface of the mold tool, and depositing a plurality of fiber strips over the thermoplastic material.

Assemblies and methods for forming fiber reinforced thermoplastic structures

Methods and apparatus' for induction welding a first workpiece to a second workpiece at a welding region may include a metallic strip. The metallic strip may be a mesh. The properties of the metallic strip, such as, for example, pore size, thickness, and density, may be configured to conduct heat uniformly across the welding region and prevent eddy current formation across a workpiece. The metallic strip may be embedded in a workpiece or may be fixed to an induction welding tool that acts on the welding region during induction welding. A removable polymer tape may be disposed between a workpiece and a metallic strip fixed to an induction welding tool. The workpieces may be thermoplastic composite structures and thermoplastic composite stiffeners in aircraft structures.

Induction welding of thermoplastic with metallic strips

During a manufacturing method, an induction welder is provided that includes a concentrator and a coil extending through a receptacle in the concentrator. The receptacle projects into the concentrator from a face surface of the concentrator. A first thermoplastic body arranged with a second thermoplastic body are provided. The first thermoplastic body is located next to the face surface. The first thermoplastic body is induction welded to the second thermoplastic body to provide a weld seam between the first thermoplastic body and the second thermoplastic body. The concentrator extends along a portion of the weld seam. The induction welding includes: generating an electromagnetic field with the coil; and concentrating a portion of the electromagnetic field with the concentrator onto a region of the first thermoplastic body.

Induction welding with an electromagnetic field concentrator

An induction welding system includes a first gantry, a second gantry, and a support structure. The first gantry includes a first frame and a first plurality of trunks. The first plurality of trunks defines a first curved inner support surface of the first gantry. The first curved inner support surface has a first curvature geometry. The second gantry includes a second frame and a second plurality of trunks. The second plurality of trunks defines a second curved inner support surface of the second gantry. The second curved inner support surface has a second curvature geometry which is different than the first curvature geometry. The support structure includes at least one tooling member defining a curved outer support surface of the support structure. The support structure is longitudinally moveable relative to the first gantry and the second gantry.

Systems and methods for induction welding

A tacking device may comprise: a handle; a main body extending from a first end of the handle to a second end of the handle; and a plurality of soldering irons, each soldering iron in the plurality of soldering irons extending from a first side of the main body through the main body to a second side of the main body, each soldering iron in the plurality of soldering irons including a piercing end disposed on the second side of the main body.

Ply tacking devices, systems, and methods

An assembly is provided for induction welding. This induction welding assembly includes a fixture. The fixture includes a first support structure and a second support structure. The second support structure includes a frame and a plurality of trunks. Each of the trunks is connected to and repositionable on the frame. The fixture is configured to secure a workpiece vertically between the first support structure and the second support structure using the trunks during induction welding of the workpiece.

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Pasadena, CA, United States of America

Jonathan S Huang