Patent Description:
In general, the welding of thermoplastic components and/or thermoplastic-based fiber-reinforced composites can provide for efficient joining of separate thermoplastic parts with benefits of cost/labor reduction, technological convenience and/or opportunities to design and optimize complex-shape structures. However, in contrast with more traditional adhesion-based bonding of thermoplastic materials or composites, welding-based joining can be associated with through-thickness physical processes, resulting in complex interconnection areas between welded parts. Conventional practice provides almost non-existent or very limited visualization of the welded interconnection areas for thermoplastic components/composites. Thermoplastic component assemblies are disclosed in <CIT>, <CIT> and <CIT>.

The present invention provides a thermoplastic component assembly as defined by claim <NUM> and a characterization method as defined by claim <NUM>. Features or embodiments are defined in the dependent claims.

Features and aspects of embodiments are described below with reference to the accompanying drawings, in which elements are not necessarily depicted to scale.

Example embodiments of the present disclosure are further described with reference to the appended figures. It is to be noted that the various features, steps, and combinations of features/steps described below and illustrated in the figures can be arranged and organized differently to result in embodiments which are still within the scope of the present disclosure. To assist those of ordinary skill in the art in making and using the disclosed assemblies, systems and methods, reference is made to the appended figures, wherein:.

The example embodiments disclosed herein are illustrative of assemblies for characterization of welded joints for thermoplastic components, and systems of the present disclosure and methods/techniques thereof. It should be understood, however, that the disclosed embodiments are merely examples of the present disclosure, which may be embodied in various forms. Presented examples show assemblies of two thermoplastic components, however, the same embodiments can be used for assemblies comprising more than two components. Therefore, details disclosed herein with reference to example assemblies for characterization of welded joints for thermoplastic components (e.g., thermoplastic-based fiber-reinforced composites) and associated processes/techniques of fabrication/assembly and use are not to be interpreted as limiting, but merely as the basis for teaching one skilled in the art how to make and use the assemblies/systems and/or alternative assemblies/systems of the present disclosure.

The present disclosure provides assemblies, systems and characterization methods of welded joints for thermoplastic components.

More particularly, the present disclosure provides assemblies, systems and characterization methods of welded joints for thermoplastic components (e.g., thermoplastic-based fiber-reinforced composites) utilizing visualization agents (e.g., pigments and/or fluorescent agents).

As noted above, current practice provides almost no or very limited visualization of the welded interconnection areas for thermoplastic components/composites. Understanding of actual physical processes in the welded interconnection areas and quantification of actual welded patterns through advanced visualization can be important for further optimization of welded processes and their cost-efficient mechanical characterization and quality inspection. For example, understanding and characterizing these interconnection areas between welded parts can be important for the acceleration of welding-based product development, the optimization of manufacturing processes, the identification of potential risks and their mitigations, and the reduction of conservatism in composite designs. In example embodiments, the present disclosure provides for assemblies, systems and characterization methods of welded joints for thermoplastic components (e.g., thermoplastic-based fiber-reinforced composites) with enhanced visualization, sufficient for qualitative and quantitative assessment of the welded interconnected areas.

<FIG> is a through-thickness cross-sectional side view of a thermoplastic component assembly <NUM>, according to certain embodiments of the present disclosure. In general, thermoplastic component assembly <NUM> includes a first thermoplastic component <NUM> and a second thermoplastic component <NUM>.

First thermoplastic component <NUM> and second thermoplastic component <NUM> each include a thermoplastic polymer material. It is noted that the thermoplastic polymer material of the first thermoplastic component <NUM> can be the same as or different than the thermoplastic polymer material of the second thermoplastic component <NUM>.

In some embodiments, the first thermoplastic component <NUM> and/or the second thermoplastic component <NUM> takes the form of a thermoplastic-based fiber-reinforced composite component <NUM>, <NUM>, (e.g., a thermoplastic material that includes fibers, such as reinforcing carbon, glass or organic (e.g., Kevlar) fibers, any of their combinations, or the like). The reinforcing fibers can be continuous fibers, short (chopped) fibers or organized as an interwoven fabric. The reinforcement layups can include, among others, laminated designs, comprising of sets of uni-directionally-reinforced or fabric plies, or 2D or 3D woven configurations.

In contrast with conventional practice where the boundary or interconnection area between welded parts can barely be seen, the present disclosure provides one or more visualization agents <NUM> (e.g., fluorescent agents <NUM>) added to the thermoplastic polymer material or matrix of the first thermoplastic component <NUM> and the second thermoplastic component <NUM> to make the boundary or interconnection area <NUM> between welded components <NUM>, <NUM> clearly observed and assessed. Fluorescent agents <NUM> and/or dyes that absorb UV light (e.g., around <NUM> wavelengths) and fluoresce in the visible spectrum are utilized to detect the clear boundary or interconnection area <NUM> between welded components <NUM>, <NUM>.

As shown in <FIG>, the first thermoplastic component <NUM> can include the visualization agent <NUM> (e.g., bright pigment <NUM> and/or fluorescent agent <NUM>) mixed with the polymer of the first thermoplastic component <NUM> for improved visual contrast of the boundary or interconnection area <NUM> between welded components <NUM>, <NUM>. It is noted that instead of or in addition to component <NUM>, the second thermoplastic component <NUM> can include the visualization agent <NUM> (e.g., bright pigment <NUM> and/or fluorescent agent <NUM>) mixed with the polymer of the second thermoplastic component <NUM> for improved visual contrast of the boundary or interconnection area <NUM> between welded components <NUM>, <NUM>.

It is noted that through-thickness cross-sectional side views or generated clear through-thickness views of assembly <NUM> as shown in <FIG> can allow one to identify the type of interconnection areas <NUM> between welded components <NUM>, <NUM>.

For example and as shown in <FIG>, the boundary or interconnection area <NUM> between welded components <NUM>, <NUM> can be identified as a distinct monotonic boundary/area <NUM> between welded components <NUM>, <NUM> (<FIG>); or the area <NUM> between welded components <NUM>, <NUM> can be identified as a distinct stochastic boundary/area <NUM> between welded components <NUM>, <NUM> with a clear boundary <NUM> between components <NUM>, <NUM> (<FIG>); or the area <NUM> between welded components <NUM>, <NUM> can be identified as a stochastic blurred interconnection area <NUM> between welded components <NUM>, <NUM>, with a mixture of the polymer from component <NUM> mixed with the polymer from component <NUM> mixed together in the boundary area <NUM> (<FIG>). In addition to the different types of qualitative assessments as shown in <FIG>, it is noted that quantitative analysis of detected boundaries/areas <NUM> of welded components <NUM>, <NUM> can be performed using measurements by typical image-processing techniques/capabilities or the like.

<FIG> is a through-thickness cross-sectional side view of another thermoplastic component assembly <NUM>. As shown in <FIG>, the first thermoplastic component <NUM> includes a first visualization agent <NUM> (e.g., first bright pigment <NUM> and/or first fluorescent agent <NUM>) mixed with the polymer of the first thermoplastic component <NUM>, and the second thermoplastic component <NUM> includes a second visualization agent 18A (e.g., second bright pigment 18A and/or second fluorescent agent 18A) mixed with the polymer of the second thermoplastic component <NUM> to visually emphasize the boundary or interconnection area <NUM> between welded components <NUM>, <NUM> (e.g., for improved visual contrast of the boundary or interconnection area <NUM> between welded components <NUM>, <NUM>).

<FIG> is a through-thickness cross-sectional side view of another thermoplastic component assembly <NUM> of the present disclosure. Thermoplastic component assembly <NUM> can include first thermoplastic component <NUM> and second thermoplastic component <NUM>, with the first thermoplastic component <NUM> including a first thermoplastic layer 12A of component <NUM>, a second thermoplastic layer 12B of component <NUM> and a third thermoplastic layer 12C of component <NUM>. It is noted that the first thermoplastic component <NUM> can include any number of thermoplastic layers 12A, 12B, 12C, 12D, etc. (e.g., component <NUM> can include three layers 12A to 12C; component <NUM> can include four layers 12A to 12D; component <NUM> can include six layers 12A to 12F; etc.). It is also noted that the definition of example layers 12A, 12B, 12C, 12D, etc. can be based on specifics of a considered visualization objective and, for example, each layer 12A, 12B, etc. can comprise one or many individual fiber-reinforced plies in the case of laminated thermoplastic composites. Similarly, the number of layers with different visualization agents can be based on specifics of considered analysis and can comprise one, two, three, four or more separate thermoplastic layers.

As shown in <FIG>, the first thermoplastic layer 12A includes a first visualization agent 18A (e.g., first bright pigment 18A and/or first fluorescent agent 18A) mixed with the polymer of the first thermoplastic component <NUM>, and the second thermoplastic layer 12B includes a second visualization agent 18B (e.g., second bright pigment 18B and/or second fluorescent agent 18B) mixed with the polymer of the first thermoplastic component <NUM>, and the third thermoplastic layer 12C includes a third visualization agent 18C (e.g., third bright pigment 18C and/or third fluorescent agent 18C) mixed with the polymer of the first thermoplastic component <NUM>, to visually emphasize the boundary or interconnection area <NUM> between welded components <NUM>, <NUM> (e.g., for improved visual contrast of the boundary or interconnection area <NUM> between welded components <NUM>, <NUM>). In certain embodiments, the first visualization agent 18A, the second visualization agent 18B and the third visualization agent 18C are all different from one another, although the present disclosure is not limited thereto.

In certain embodiments, the thickness or height of each layer 12A, 12B, 12C is substantially uniform or similar, although the present disclosure is not limited thereto.

In some embodiments, assembly <NUM> can include a plurality of first layers 12A with first visualization agent 18A (e.g., two first layers 12A; three first layers 12A; a plurality of first layers 12A; etc.), with each additional first layer 12A stacked on top of a respective first layer 12A.

Similarly, assembly <NUM> can include a plurality of second layers 12B with second visualization agent 18B (e.g., two second layers 12B; three second layers 12B; a plurality of second layers 12B; etc.), with each additional second layer 12B stacked on top of a respective second layer 12B.

Likewise, assembly <NUM> can include a plurality of third layers 12C with third visualization agent 18C (e.g., two third layers 12C; three third layers 12C; a plurality of third layers 12C; etc.), with each additional third layer 12C stacked on top of a respective third layer 12C.

In other embodiments and as shown in <FIG>, thermoplastic component assembly <NUM> can include first thermoplastic component <NUM> and second thermoplastic component <NUM>, with the first thermoplastic component <NUM> including a first thermoplastic layer 12A of component <NUM>, a second thermoplastic layer 12B of component <NUM> and a third thermoplastic layer 12C of component <NUM>, and with the second thermoplastic component <NUM> including a first thermoplastic layer 14A of component <NUM>, a second thermoplastic layer 14B of component <NUM> and a third thermoplastic layer 14C of component <NUM>.

As similarly described with respect to <FIG>, the first thermoplastic layer 12A includes a first visualization agent 18A mixed with the polymer of the first thermoplastic component <NUM>, and the second thermoplastic layer 12B includes a second visualization agent 18B mixed with the polymer of the first thermoplastic component <NUM>, and the third thermoplastic layer 12C includes a third visualization agent 18C mixed with the polymer of the first thermoplastic component <NUM>.

Moreover, the first thermoplastic layer 14A of component <NUM> includes a fourth visualization agent 18D (e.g., fourth bright pigment 18D and/or fourth fluorescent agent 18D) mixed with the polymer of the second thermoplastic component <NUM>, and the second thermoplastic layer 14B of component <NUM> includes a fifth visualization agent 18E (e.g., fifth bright pigment 18E and/or fifth fluorescent agent 18E) mixed with the polymer of the second thermoplastic component <NUM>, and the third thermoplastic layer 14C of component <NUM> includes a sixth visualization agent 18F (e.g., sixth bright pigment 18F and/or sixth fluorescent agent 18F) mixed with the polymer of the second thermoplastic component <NUM>. In certain embodiments, the fourth visualization agent 18D, the fifth visualization agent 18E and the sixth visualization agent 18F are all different from one another, although the present disclosure is not limited thereto.

In certain embodiments, the thickness or height of each layer 14A, 14B, 14C is substantially uniform or similar, although the present disclosure is not limited thereto.

In some embodiments, assembly <NUM> can include a plurality of first layers 14A with fourth visualization agent 18D (e.g., two first layers 14A; three first layers 14A; a plurality of first layers 14A; etc.), with each additional first layer 14A stacked on top of a respective first layer 14A.

Similarly, assembly <NUM> can include a plurality of second layers 14B with fifth visualization agent 18E (e.g., two second layers 14B; three second layers 14B; a plurality of second layers 14B; etc.), with each additional second layer 14B stacked on top of a respective second layer 14B.

Likewise, assembly <NUM> can include a plurality of third layers 14C with sixth visualization agent 18F (e.g., two third layers 14C; three third layers 14C; a plurality of third layers 14C; etc.), with each additional third layer 14C stacked on top of a respective third layer 14C.

As shown in <FIG>, thermoplastic component assembly <NUM> can include first thermoplastic component <NUM> and second thermoplastic component <NUM>, with the first thermoplastic component <NUM> including a first thermoplastic layer 12A of component <NUM>, a second thermoplastic layer 12B of component <NUM>, a third thermoplastic layer 12C of component <NUM>, and a fourth thermoplastic layer 12D of component <NUM>.

As similarly described above, the first thermoplastic layer 12A includes a first visualization agent 18A, the second thermoplastic layer 12B includes a second visualization agent 18B, the third thermoplastic layer 12C includes a third visualization agent 18C, and the fourth thermoplastic layer 12D includes a fourth visualization agent 18D (e.g., fourth bright pigment 18D and/or fourth fluorescent agent 18D) mixed with the polymer of the first thermoplastic component <NUM>, to visually emphasize the boundary or interconnection area <NUM> between welded components <NUM>, <NUM> (e.g., for improved visual contrast of the boundary or interconnection area <NUM> between welded components <NUM>, <NUM>). In certain embodiments, the first visualization agent 18A, the second visualization agent 18B, the third visualization agent 18C, and the fourth visualization agent 18D are all different from one another, although the present disclosure is not limited thereto.

In certain embodiments, the thickness or height of each layer 12A, 12B, 12C, 12D can vary from one another, although the present disclosure is not limited thereto.

For example and as shown in <FIG>, the thickness of first layer 12A can be thinner or smaller than the thickness of second layer 12B, and the thickness of second layer 12B can be thinner or smaller than the thickness of third layer 12C, and the thickness of third layer 12C can be thinner or smaller than the thickness of fourth layer 12D. In this way, the layers closer to interconnection area <NUM> can be thinner than the layers above them.

As similarly described above, assembly <NUM> can include a plurality of first layers 12A with first visualization agent 18A, and/or a plurality of second layers 12B with second visualization agent 18B, and/or a plurality of third layers 12C with third visualization agent 18C, and/or a plurality of third layers 12C with third visualization agent 18C.

<FIG> depicts assembly <NUM> similar to <FIG>, and with assembly <NUM> of <FIG> including a fifth layer 12E of component <NUM>, with the fifth layer 12E not including a visualization agent <NUM>. It is noted that assembly <NUM> can include other layers of component <NUM> that do not include a visualization agent <NUM>. In this was an as depicted in <FIG>, the fifth layer 12E (or layers) that is farthest away from interconnection area <NUM> may not include a visualization agent <NUM>.

<FIG> is a side perspective view of another example thermoplastic component assembly <NUM>. It is noted that the thermoplastic component assembly <NUM> of <FIG> can take the form of any of the assemblies <NUM> or alternative assemblies <NUM> discussed above with respect to <FIG>.

As shown in <FIG>, assembly <NUM> can include a first excess portion <NUM> and a second excess portion 20A. In general, first and second excess portions <NUM>, 20A each include portions of component <NUM> and/or <NUM>. It is noted that assembly <NUM> may only include first excess portion <NUM> or second excess portion 20A, or may include other excess portions 20B, 20C, etc..

After welding first thermoplastic component <NUM> to second thermoplastic component <NUM>, the first excess portion <NUM> can be cut away or removed from assembly <NUM> along surface A-A of <FIG>, and the second excess portion <NUM> can be cut away or removed from assembly <NUM> along surface B-B of <FIG>. As such, side views of the interconnection areas <NUM> along surfaces A-A and B-B of assembly <NUM> after removal of portions <NUM>, 20A can provide for monitoring of structural behavior during operation of assembly <NUM> and/or under testing with applied load of assembly <NUM>, and can provide key input on potential risks and ways for their mitigation (e.g., for interconnection areas <NUM> of assembly <NUM>).

The analysis as provided by the removal of portions <NUM>, 20A allows for accelerated development of welding technology, understanding of potential risks associated with thermoplastic welding, and overall design optimization of welded assembly <NUM>.

There are many benefits of the assemblies, systems and methods of the present disclosure, including, without limitation: acceleration of thermoplastic product development, using welding process; clear qualitative and quantitative metrics of welding process for benchmarking and optimization; and/or the opportunity to utilize with both aircraft and non-aircraft applications/components.

While particular embodiments have been described, alternatives are possible that fall within the scope of the claims.

The ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other (e.g., ranges of "up to <NUM> wt. %, or, more specifically, <NUM> wt. % to <NUM> wt. %", is inclusive of the endpoints and all intermediate values of the ranges of "<NUM> wt. % to <NUM> wt. "Combinations" is inclusive of blends, mixtures, reaction products, and the like. The terms "first," "second," and the like, do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The terms "a" and "an" and "the" do not denote a limitation of quantity and are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. "Or" means "and/or" unless clearly stated otherwise. Reference throughout the specification to "some embodiments", "an embodiment", and so forth, means that a particular element described in connection with the embodiment is included in at least one embodiment described herein, and may or may not be present in other embodiments.

Although the systems and methods of the present disclosure have been described with reference to example embodiments thereof, the present disclosure is not limited to such example embodiments and/or implementations. Rather, the systems and methods of the present disclosure are susceptible to many implementations and applications, as will be readily apparent to persons skilled in the art from the disclosure hereof, that fall within the scope of the claims.

Claim 1:
A thermoplastic component assembly comprising:
a first thermoplastic component (<NUM>) comprising a first thermoplastic polymer material, the first thermoplastic polymer material comprising a first visualization agent; and
a second thermoplastic component (<NUM>) comprising a second thermoplastic polymer material comprising a second visualization agent;
wherein the first visualization agent and the second visualization agent are configured to operate as visual contrast under lighting conditions to identify a boundary or interconnection area (<NUM>) between the first thermoplastic component welded to the second thermoplastic component;
characterised in that the first visualization agent and the second visualization agent are fluorescent agents and/or dyes and absorb UV light and fluoresce in the visible spectrum.