Method and apparatus for welding of polymer composite components

An apparatus for welding together a plurality of as-formed polymer composite components, the as-formed composite components having adjacent thermoplastic surfaces in vicinity of at least one intended weld joint, the apparatus comprising:

• at least one location device having one or more locators to retain a plurality of as-formed composite components to be welded, at the adjacent thermoplastic surfaces thereof, in a three dimensional arrangement relative to each other;
• a flexible pressure application device for transferring pressure to each of the adjacent thermoplastic surfaces so as to urge the adjacent thermoplastic surfaces together to form the intended weld joint;
• a heating device configured to raise a temperature locally at the adjacent thermoplastic surfaces to be welded, in cooperation with the flexible pressure application device urging the adjacent thermoplastic surfaces together, and to weld the adjacent thermoplastic surfaces of the as-formed composite components together;
• a load bearing structure for supporting the flexible pressure application device against at least one of the as-formed composite components in the vicinity of the intended weld joint;
• wherein the flexible pressure application device comprises at least one pressure bladder assembly, each assembly having a flexible contact surface through which pressure is applied to the surface of the at least one as-formed composite component;
• and
• wherein a heated fluid is used to inflate the pressure application device and simultaneously apply heat to the outer surface of at least one as-formed composite component.

An apparatus for welding together a plurality of as-formed polymer composite components, the as-formed composite components having adjacent thermoplastic surfaces in vicinity of at least one intended weld joint, the apparatus comprising:

• at least one location device having one or more locators to retain a plurality of as-formed composite components to be welded, at the adjacent thermoplastic surfaces thereof, in a three dimensional arrangement relative to each other;
• a flexible pressure application device for transferring pressure to each of the adjacent thermoplastic surfaces so as to urge the adjacent thermoplastic surfaces together to form the intended weld joint;
• a heating device configured to raise a temperature locally at the adjacent thermoplastic surfaces to be welded, in cooperation with the flexible pressure application device urging the adjacent thermoplastic surfaces together, and to weld the adjacent thermoplastic surfaces of the as-formed composite components together;
• a load bearing structure for supporting the flexible pressure application device against at least one of the as-formed composite components in the vicinity of the intended weld joint;
• wherein the load bearing structure for supporting the heating device and pressure application device comprises at least one form block, the form block being supported against the load bearing structure and positioned to be able to apply pressure to the at least one as-formed component structure in the vicinity of the intended weld joint;
• and
• wherein the position of the form block is adjustable horizontally and vertically to accommodate different three dimensional arrangements of as-formed composite structures and weld joints to be welded.