Spirit AeroSystems. has developed a system and method for fusing thermoplastic composite components using conductive fibers and a multi-layer composite pressure pad. The innovative process involves induction welding to join the components, ensuring a strong bond. GlobalData’s report on Spirit AeroSystems gives a 360-degree view of the company including its patenting strategy. Buy the report here.
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According to GlobalData’s company profile on Spirit AeroSystems, Photovoltaic drones was a key innovation area identified from patents. Spirit AeroSystems's grant share as of January 2024 was 56%. Grant share is based on the ratio of number of grants to total number of patents.
Induction welding system for thermoplastic composite components
A newly filed patent (Publication Number: US20230398748A1) describes a system and method for fusing thermoplastic composite components together using induction welding. The system includes a composite part with two thermoplastic composite components, each with faying surfaces, conductive fibers, and matrix materials. A multi-layer composite pressure pad, consisting of a first layer with non-conductive reinforcement and a second layer that remains rigid at high temperatures, is placed over the components. An inductor is activated to heat the faying surfaces for fusion via induction welding. Additionally, a separation layer may be used to protect non-faying surfaces during the process.
The method involves placing the thermoplastic composite components together, adding a separation layer, and placing the multi-layer composite pressure pad over them. The activated inductor then induction welds the faying surfaces together. The separation layer, typically a release film, has a higher melting point than the matrix materials of the components and the pressure pad. Conduction from the components melts the pressure pad's matrix material, creating a melted portion that remains contained within the pad. This innovative system and method offer a precise and efficient way to fuse thermoplastic composite components, ensuring a strong bond between the materials.
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