# US 11,077,624 B2 · System and method for welding thermoplastic components to create composite structure > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,077,624 B2 - Document ID: US11077624B2 - Status: Granted - Kind: B2 - Application number: 16/874,069 - Filed: 2020-05-14 - Published: 2020-08-27 - Granted: 2021-08-03 - Earliest claimed: 2018-06-20 - Assignees: Spirit AeroSystems, Inc. - Applicants: Spirit AeroSystems, Inc. - Inventors: Mark Anthony Wadsworth - Web page: https://patentgrep.com/patent/US11077624B2 ## CPC - B29C 65/2053: {characterised by special ways of bringing the welding mirrors into position} - B29C 66/73921: {characterised by the materials of both parts being thermoplastics} - B29C 65/103: {direct heating both surfaces to be joined} - B29C 65/1412: {Infrared [IR] radiation} - B29C 65/1432: {direct heating of the surfaces to be joined} - B29C 65/1458: {once, i.e. contour welding} - B29C 65/20: with direct contact, e.g. using "mirror" - B29C 65/30: Electrical means {(B29C65/38 takes precedence)} - B29C 65/72: by combined operations {or combined techniques}, e.g. welding and stitching - B29C 66/00141: {Protective gases} - B29C 66/0342: {Cooling, e.g. transporting through welding and cooling zone} - B29C 66/112: {Single lapped joints} - B29C 66/131: {Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area} - B29C 66/43: {Joining a relatively small portion of the surface of said articles (B29C66/45 takes precedence)} - B29C 66/524: {Joining profiled elements} - B29C 66/532: {Joining single elements to the wall of tubular articles, hollow articles or bars} - B29C 66/61: {Joining from or joining on the inside (for making tubes by bending sheets and joining from the inside B29C53/387)} - B29C 66/721: {Fibre-reinforced materials (B29C66/729 takes precedence)} - B29C 66/80: {General aspects of machine operations or constructions and parts thereof} - B29C 66/8181: {characterised by the cooling constructional aspects} - B29C 66/8362: {Rollers, cylinders or drums moving relative to and tangentially to the parts to be joined} - B29C 66/863: {Robotised, e.g. mounted on a robot arm} - B29C 66/91212: {involving measurement means being part of the welding jaws, e.g. integrated in the welding jaws} - B29C 66/91216: {enabling contactless temperature measurements, e.g. using a pyrometer} - B29C 66/91221: {of the parts to be joined} - B29C 66/91231: {of the joining tool} - B29C 66/9161: {by controlling or regulating the heat or the thermal flux, i.e. the heat flux} - B29C 66/934: {by controlling or regulating the speed} - B29C 66/961: {involving a feedback loop mechanism, e.g. comparison with a desired value} - B64C 1/12: Construction or attachment of skin panels - B29C 65/08: using ultrasonic vibrations {(non-plastics element to plastics elements B29C65/645)} - B29C 65/3492: {being carbon} - B29C 65/36: heated by induction - B29C 65/40: Applying molten plastics, e.g. hot melt (using welding bar {combined with hot gases} B29C65/12; by moulding B29C65/70) - B29C 65/42: between pre-assembled parts {(B29C65/605 takes precedence)} - B29C 65/4815: {Hot melt adhesives, e.g. thermoplastic adhesives} - B29C 65/5014: {being fibre-reinforced (B29C65/5028 takes precedence)} - B29C 65/5057: {positioned between the surfaces to be joined (B29C65/5035 takes precedence)} - B29C 65/542: {by injection} - B29L 2031/3076: {Aircrafts (blades, propellers B29L2031/08)} - B64C 2001/0072: {from composite materials} - Y02T 50/40: Weight reduction - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B64C: AEROPLANES; HELICOPTERS - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES - Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION ## Abstract A system and method for welding thermoplastic components by positioning and moving a heated plate between the components to melt their respective faying surfaces, and as the plate moves, pressing the components together so that the melted faying surfaces bond together as they cool and re-solidify, thereby creating a composite structure. The plate has a heated portion which is positioned between and heated to melt a portion of the first and second faying surfaces. A manipulator mechanism moves the plate along an interface from between the portion to between a series of subsequent portions of the first and second faying surfaces, thereby welding the thermoplastic components along the entire interface to create the composite structure. The heated portion may contact the faying surfaces and melt them through conduction, or may be suspended between them and melt them through radiation and convection. ## Claims ### Claim 1 A system for welding a first thermoplastic component to a second thermoplastic component along an interface to create a composite structure, the system comprising: a plate comprising a heated portion positioned between a portion of a first faying surface of the first thermoplastic component and a second faying surface of the second thermoplastic component, the heated portion being heated to a temperature which is sufficient to melt the portion of the first and second faying surfaces; and a manipulator mechanically coupled with the plate and moving the plate along the interface from between the portion of the first and second faying surfaces, which then cool and bond together, to between a series of subsequent portions of the first and second faying surfaces. ### Claim 2 (depends on 1) The system of claim 1, the heated portion the plate comprising a thickness of between 0.01 inches and 0.03 inches. ### Claim 3 (depends on 1) The system of claim 1, the heated portion of the plate being heated using joule heating. ### Claim 4 (depends on 1) The system of claim 1, further comprising a first temperature sensor determining the operating temperature of the plate, and a second temperature sensor determining an adjacent temperature of the first and second thermoplastic components. ### Claim 5 (depends on 1) The system of claim 1, at least the heated portion of the plate being in physical contact with the first and second faying surfaces, and melting the first and second faying surfaces through conduction. ### Claim 6 (depends on 5) The system of claim 5, a front portion of the plate comprising a rake angle to control any excess melted thermoplastic material from the first and second faying surfaces. ### Claim 7 (depends on 6) The system of claim 6, the rake angle being between 10 degrees and 50 degrees. ### Claim 8 (depends on 1) The system of claim 1, at least the heated portion of the plate being suspended between and not in physical contact with the first and second faying surfaces, and melting the first and second faying surfaces through radiation and convection. ### Claim 9 (depends on 8) The system of claim 8, further comprising a spacer creating a gap between the first and second faying surfaces, and at least the heated portion of the plate being located in the gap. ### Claim 10 (depends on 9) The system of claim 9, the spacer being an unheated front portion of the plate. ### Claim 11 (depends on 9) The system of claim 9, the spacer comprising one or more circular rollers. ### Claim 12 (depends on 8) The system of claim 8, further comprising an air nozzle introducing a stream of air between at least the heated portion of the plate and the first and second faying surfaces so as to enhance convection. ### Claim 13 (depends on 8) The system of claim 8, further comprising one or more holes in the plate to enhance convection. ### Claim 14 (depends on 1) The system of claim 1, the manipulator further comprising a guide roller guiding movement of the plate along the interface between the first and second faying surfaces. ### Claim 15 (depends on 1) The system of claim 1, the manipulator further comprising a pressure roller pressing the first and second faying surfaces together behind the plate as the plate is moved along the interface. ### Claim 16 (depends on 1) The system of claim 1, the manipulator further comprising a cooling nozzle delivering a cooling fluid to accelerate cooling of the first and second faying surfaces behind the plate as the plate is moved along the interface. ### Claim 17 (depends on 1) The system of claim 1, the manipulator further comprising an inert gas nozzle delivering an inert gas to displace oxygen around the heated portion of the plate. ### Claim 18 (depends on 1) The system of claim 1, further comprising a support surface positioned behind the second thermoplastic component, the support surface being flexible so as to accommodate a deflection of the second thermoplastic component as the plate is moved between the first and second faying surfaces. ### Claim 19 A method for welding a first thermoplastic component to a second thermoplastic component along an interface to create a composite structure, the method comprising: positioning a plate between a portion of a first faying surface of the first thermoplastic component and a second faying surface of the second thermoplastic component; heating at least a portion of the plate to a temperature which is sufficient to melt the portion of the first and second faying surfaces; and moving the plate with a manipulator mechanically coupled with the plate along the interface from between the portion of the first and second faying surfaces, which then cool and bond together, to between a series of subsequent portions of the first and second faying surfaces. ### Claim 20 A method for welding a first thermoplastic component to a second thermoplastic component, the method comprising: positioning a plate between a portion of a first surface of the first thermoplastic component and a second surface of the second thermoplastic component; heating at least a portion of the plate to a temperature which is sufficient to melt the portion of the first and second surfaces; and moving the plate from between the portion of the first and second surfaces, which then cool and bond together, to between a series of subsequent portions of the first and second surfaces.