Induction welding using a heat sink and/or cooling

A system for dissipating heat from a surface of a first thermoplastic composite (TPC) as the first TPC is inductively welded to a second thermoplastic composite (TPC), the system comprising:

• a heat sink disposed on and flexibly conforming to the surface of the first TPC, the heat sink having a number of tiles flexibly joined together by a joint, wherein the heat sink covers a weld interface area formed between the first TPC aligned with the second TPC;
• an induction coil disposed above the heat sink and moveable relative to the weld interface area in a first direction to apply inductive heat to the weld interface area and form a weld at the weld interface area between the first TPC with the second TPC, wherein the heat sink draws off heat from the surface of the first TPC;
• and
• a cooling apparatus disposed above the heat sink for cooling the heat sink, the cooling apparatus disposed adjacent the induction coil in the first direction, the cooling apparatus moveable in the first direction to cool the heat sink prior to inductively heating the weld interface area and forming the weld.

A method of dissipating heat from a surface of a first thermoplastic composite (TPC) being inductively welded with a second thermoplastic composite (TPC), the method comprising:

• aligning the first TPC with the second TPC to form a weld interface area between the first TPC and the second TPC
• placing a heat sink on the surface of the first TPC and flexing the heat sink to conform to the surface of the first TPC, wherein the heat sink covers the weld interface area;
• cooling the heat sink before inductively heating the weld interface area;
• 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
• cooling the heat sink after inductively heating.