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US 12,686,181 B2Granted
Induction welding of composite structures
AssigneeThe Boeing Company
InventorsEmma Louise Morrissey, Ying Shi, Francis J. Samalot, Gregory J. Hickman
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Abstract
A composite structure and methods of forming composite structures are provided. A composite structure comprises a first composite part; a second composite part welded to the first composite part at a joint; and the joint between the first composite part and the second composite part comprising doped fibers.
Claims21
A composite structure that comprises:
- a first composite part that comprises a plurality of thermoplastic plies and a doped prepreg ply that comprises graphene grown on fibers within only a first surface on the first composite part, doped in a resin and configured to generate heat without metallic additives;
- and
- a second composite part that comprises a second plurality of thermoplastic plies and a second doped prepreg ply that comprises a second graphene grown on second fibers within only a second surface on the second composite part, doped in a second resin and configured to generate heat without metallic additives, wherein the second composite part is induction welded to the first composite part where the doped prepreg ply contacts the second doped prepreg ply.
A method of welding two composite parts to form a composite structure, the method comprising:
- forming a first composite part comprising a plurality of thermoplastic plies and a first surface;
- doubling a heat energy generation characteristic of only the first surface by growing vertical graphene from fibers existing in the first surface and then doping the fibers existing in the first surface with a resin and forming the first surface as a doped prepreg ply;
- positioning a second composite part in contact with the first surface such that the doped prepreg ply contacts the second composite part;
- and
- generating, from an induction welding coil receiving a current insufficient for welding the first surface before modifying the first surface into the doped prepreg ply, a current forming an electromagnetic field welding the first composite part to the second composite part using heat generated only by the fibers in the doped prepreg ply responding to the electromagnetic field.
2 more elements
A method comprising:
- forming a first composite part comprising a plurality of thermoplastic plies and a first surface;
- doubling a heat energy generation characteristic of only the first surface by growing vertical graphene from fibers existing in the first surface and then doping the fibers existing in the first surface with a resin, without metal additives, and;
- positioning a second composite part relative to the first composite part such that the doped prepreg ply contacts the second composite part;
- and
- generating, from an induction welding coil receiving a current insufficient for welding the first surface before modifying the first surface into the doped prepreg ply, a current forming an electromagnetic field welding only the first composite part and the second composite part together using heat generated by the doped prepreg ply responding to the electromagnetic field.
2 more elements
Dependencies are inferred from the claim text.