Patent Description:
A workpiece may be induction welded to bond members of that workpiece together. Various fixtures are known in the art for induction welding. Typically, an induction welding fixture is specifically tailored for induction welding a single joint on the workpiece. Therefore, a workpiece with multiple weld joints may require multiple different fixtures. Alternatively, a single fixture may be configured with multiple stations for induction welding the workpiece at different locations. Such a multi-station fixture may be arranged with the workpiece such that an induction welding coil can weld the workpiece without moving the workpiece or the fixture. While the known fixtures have various benefits, these fixtures may be expensive to produce and tedious to setup for induction welding. There is a need in the art therefore for a more versatile fixture for induction welding.

<CIT> discloses an apparatus for induction welding of thermoplastics comprising a tooling support including lower headers, end tube members and upper headers connected to and repositionable on the end tube members, the tooling support configured to secure a workpiece vertically between the lower header and the upper headers during induction welding.

<CIT> discloses welding thermoplastic structures.

<CIT> discloses induction welding for thermoplastic composite parts.

According to an aspect of the present invention, an assembly is provided for induction welding as claimed in claim <NUM>.

Embodiments of this aspect of the invention are provided in claims dependent from claim <NUM>.

According to another aspect of the present invention, an induction welding method is provided as claimed in claim <NUM>.

<FIG> illustrates a system <NUM> for induction welding a workpiece <NUM>. This induction welding system <NUM> includes an induction welder <NUM> and an induction welding fixture <NUM>.

The induction welder <NUM> is configured to induction weld the workpiece <NUM>. More particularly, the induction welder <NUM> is configured to induction weld two or more members 28A and 28B (generally referred to as "<NUM>") of the workpiece <NUM> together, which workpiece members <NUM> may be (e.g., discretely formed) thermoplastic bodies or any other type of induction weldable bodies. The induction welder <NUM> of <FIG> includes a power source <NUM> and an induction coil assembly <NUM>.

The power source <NUM> is configured to generate a periodic electrical current. The power source <NUM>, for example, may be configured as a high-frequency current source. The power source <NUM> may be or otherwise include an alternating current (AC) generator, transformer, amplifier, etc. Alternatively, the power source <NUM> may include a direct current (DC) generator, transformer, amplifier, battery, etc. electrically coupled with an oscillator. The present disclosure, however, is not limited to such exemplary power sources.

Referring to <FIG>, the induction coil assembly <NUM> includes an electrical first lead <NUM>, an electrical second lead <NUM> and an induction welding coil <NUM>. The first lead <NUM> may be arranged parallel with the second lead <NUM>. The first lead <NUM> and the second lead <NUM> are connected to opposing ends of the induction welding coil <NUM>. The first lead <NUM> and the second lead <NUM> electrically couple the induction welding coil <NUM> to respective terminals <NUM> and <NUM> of the power source <NUM>.

The induction welding coil <NUM> may be configured as an elongated loop. The induction welding coil <NUM> of <FIG>, for example, extends along a non-straight (e.g., generally racetrack shaped) centerline between and to the coil ends. The induction welding coil <NUM> of <FIG> includes at least one welding (e.g., bottom side) segment <NUM>. This welding segment <NUM> may be configured to substantially match an exterior surface contour of the workpiece <NUM> to be induction welded. The welding segment <NUM>, for example, may be straight where the workpiece <NUM> has a flat exterior surface <NUM>. The welding segment <NUM> may alternatively be non-straight (e.g., curved, compound, etc.) where the workpiece exterior surface <NUM> is a non-straight; e.g., curved, compound, etc. The present disclosure, however, is not limited to the foregoing exemplary induction welding coil configurations.

Referring to <FIG>, the induction welding fixture <NUM> is configured to position and secure (e.g., temporarily, fixedly hold) the workpiece <NUM> during induction welding. More particularly, the induction welding fixture <NUM> is configured to position and secure the workpiece members <NUM> together while those members <NUM> are induction welded together using the induction welding coil <NUM>.

The induction welding fixture <NUM> of <FIG> includes a first (e.g., bottom, base) support structure <NUM> and a second (e.g., top, lid) support structure <NUM>. For ease of description, the first support structure <NUM> is referred to below as a "bottom support structure" and the second support structure <NUM> is referred to below as a "top support structure". However, the present disclosure is not limited to such an exemplary orientation relative to gravity. For example, in other embodiments, the support structure <NUM> may be arranged vertically below, or to a side of, the support structure <NUM>.

Referring to <FIG>, the bottom support structure <NUM> includes a support structure base <NUM>, a bottom heat management device <NUM> (e.g., a heat sink or an insulator) and an actuator <NUM>. The support structure base <NUM> extends longitudinally (e.g., along an x-axis) between and to a first end <NUM> of the support structure base <NUM> and a second end <NUM> of the support structure base <NUM>. The support structure base <NUM> extends laterally (e.g., along a y-axis) between and to a first side <NUM> of the support structure base <NUM> and a second side <NUM> of the support structure base <NUM>. The support structure base <NUM> extends vertically (e.g., along a z-axis) between and to a bottom side <NUM> of the support structure base <NUM> and a top side <NUM> of the support structure base <NUM>.

Referring to <FIG>, the support structure base <NUM> is configured with a receptacle <NUM> adapted to receive the workpiece <NUM> (see <FIG>). The support structure base <NUM> is also configured with a channel <NUM> configured to receive the bottom heat management device <NUM> and the actuator <NUM>.

The workpiece receptacle <NUM> may be configured as a channel or a depression in the base top side <NUM>. The workpiece receptacle <NUM> of <FIG>, for example, is located at (e.g., on, adjacent or proximate) the base top side <NUM>, and intermediate (e.g., midway) laterally between the opposing base sides <NUM> and <NUM>. The workpiece receptacle <NUM> extends vertically into the support structure base <NUM> from the base top side <NUM> to a receptacle end surface <NUM> of the support structure base <NUM>. The workpiece receptacle <NUM> extends laterally within the support structure base <NUM> between and to opposing receptacle side surfaces 76A and 76B (generally referred to as "<NUM>") of the support structure base <NUM>. The workpiece receptacle <NUM> extends longitudinally through (or within) the support structure base <NUM> between and to or about the opposing base ends <NUM> and <NUM> (see <FIG>).

The base channel <NUM> is also located at (e.g., on, adjacent or proximate) the base top side <NUM>, and intermediate (e.g., midway) laterally between the opposing base sides <NUM> and <NUM> and the opposing receptacle side surfaces <NUM>. The base channel <NUM> of <FIG>, for example, extends vertically into the support structure base <NUM> from the receptacle end surface <NUM> to a channel end surface <NUM> of the support structure base <NUM>. The base channel <NUM> extends laterally within the support structure base <NUM> between and to opposing channel sides surfaces 80A and 80B (generally referred to as "<NUM>") of the support structure base <NUM>. The base channel <NUM> extends longitudinally through (or within) the support structure base <NUM> between and to or about the opposing base ends <NUM> and <NUM> (see <FIG>). The support structure base <NUM> of the present disclosure, however, is not limited to such an exemplary channel configuration. For example, in other embodiments, the base channel <NUM> may extends vertically into the support structure base <NUM> from the base top side <NUM> where, for example, the workpiece receptacle <NUM> is omitted.

The support structure base <NUM> may be constructed from a non-electrically conductive material. This non-electrically conductive material may be a polymer such as, but not limited to, polyurethane. The present disclosure, however, is not limited to the foregoing exemplary support structure base materials.

The bottom heat management device <NUM> may be or otherwise include a heat sink configured to absorb heat energy. The bottom heat management device <NUM>, for example, may be constructed from a ceramic such as, but not limited to, aluminum silicate (also referred to as alumina silicate). The present disclosure, however, is not limited to the foregoing exemplary first heat sink materials. Furthermore, in other embodiments, the bottom heat management device <NUM> may be or otherwise include an insulator. The heat management device <NUM>, for example, may be configured to absorb and/or block transfer of heat energy.

The bottom heat management device <NUM> of <FIG> extends laterally between and to a first side <NUM> of the bottom heat management device <NUM> and a second side <NUM> of the bottom heat management device <NUM>. The bottom heat management device <NUM> extends vertically between and to a bottom side <NUM> of the bottom heat management device <NUM> and a top side <NUM> of the bottom heat management device <NUM>. Referring to <FIG>, the bottom heat management device <NUM> extends longitudinally between and to opposing ends 90A and 90B (generally referred to as "<NUM>") of the bottom heat management device <NUM>).

The bottom heat management device <NUM> of <FIG> is mated with (e.g., received within) the base channel <NUM>. The heat management device first side <NUM> is abutted laterally against and moveable (e.g., slidable) along the channel first side surface 80A. The heat management device second side <NUM> is abutted laterally against and moveable (e.g., slidable) along the channel second side surface 80B. The heat management device bottom side <NUM> faces the channel end surface <NUM>. The heat management device top side <NUM> faces away from the support structure base <NUM>; e.g., in a vertical upwards direction.

The actuator <NUM> is mated with (e.g., received within) the base channel <NUM>, and arranged vertically between the channel end surface <NUM> and the bottom heat management device <NUM>. The actuator <NUM> is configured to push (e.g., bias) the bottom heat management device <NUM> vertically away from the support structure base <NUM> and its channel end surface <NUM>. The actuator <NUM> of <FIG>, for example, is configured as an expandable pressure vessel <NUM>; e.g., fluid bladder such as, but not limited to, an expandable air tube, an expandable air bag, etc. This pressure vessel <NUM> is connected to a fluid source <NUM>; e.g., a compressed air reservoir (e.g., a tank) and/or an air pump. The pressure vessel <NUM> is configured to receive fluid (e.g., compressed air) from the fluid source <NUM>, where regulation of the fluid may cause the pressure vessel <NUM> to expand or contract in size. When the pressure vessel <NUM> expands in size, the fixed channel surfaces <NUM> and <NUM> may cause the pressure vessel <NUM> to expand in a vertically upward direction and thereby push the bottom heat management device <NUM> vertically within the base channel <NUM> away from the channel end surface <NUM>. However, when the pressure vessel <NUM> contracts in size, the pressure vessel <NUM> may contract in a vertically downward direction and the bottom heat management device <NUM> may move vertically within the base channel <NUM> towards from the channel end surface <NUM>.

In some embodiments, a spacer <NUM> may be disposed within the base channel <NUM> vertically between the pressure vessel <NUM> and the bottom heat management device <NUM>. This spacer <NUM> may be configured to provide a thermal break / a thermal insulator between the bottom heat management device <NUM> and the pressure vessel <NUM>. The spacer <NUM>, for example, may be constructed from a thermally insulating material such as, but not limited to, silicon.

Referring to <FIG>, the top support structure <NUM> includes a frame <NUM>, a plurality of trunks <NUM> and a top heat sink <NUM>. The top support structure <NUM> of <FIG> also includes a top heat sink holder <NUM>.

Referring to <FIG>, the support structure frame <NUM> extends longitudinally between and to a first end <NUM> of the support structure frame <NUM> and a second end <NUM> of the support structure frame <NUM>. The support structure frame <NUM> extends laterally between and to a first side <NUM> of the support structure frame <NUM> and a second side <NUM> of the support structure frame <NUM>. The support structure frame <NUM> extends vertically between and to a bottom side <NUM> of the support structure frame <NUM> and a top side <NUM> of the support structure frame <NUM>.

The support structure frame <NUM> of <FIG> includes one or more frame beams 118A and 118B (generally referred to as "<NUM>"). These frame beams <NUM> are arranged parallel with one another. Each of the frame beams <NUM> extends longitudinally between and to (or about) the opposing frame ends <NUM> and <NUM>. Each of the frame beams <NUM> extends vertically between and to the opposing frame sides <NUM> and <NUM>. The first beam 118A is arranged at (e.g., on, adjacent or proximate) the frame first side <NUM>. The second beam 118B is arranged at (e.g., on, adjacent or proximate) the frame second side <NUM>. The first beam 118A and the second beam 118B are laterally displaced from one another by an inter-beam channel <NUM>.

Referring to <FIG>, each of the frame beams <NUM> may have a channeled (e.g., C-channel) cross-sectional geometry when viewed, for example, in a plane perpendicular to the longitudinal x-axis; e.g., plane of <FIG>. The support structure frame <NUM> of the present disclosure, however, is not limited to such an exemplary frame beam configuration.

The support structure frame <NUM> and each of its beams <NUM> may be constructed from metal such as, but not limited to, steel. The present disclosure, however, is not limited to such exemplary support structure frame materials.

Referring to <FIG>, each trunk <NUM> is configured as a support block. Each trunk <NUM>, for example, extends longitudinally between and to a first end <NUM> of the respective trunk <NUM> and a second end <NUM> of the respective trunk <NUM>. Each trunk <NUM> extends laterally between a first side <NUM> of the respective trunk <NUM> and a second side <NUM> of the respective trunk <NUM>. Each trunk <NUM> extends vertically between a bottom side <NUM> of the respective trunk <NUM> and a top side <NUM> of the respective trunk <NUM>.

Each trunk of <FIG> includes a trunk base <NUM> and a trunk protrusion <NUM>; e.g., a clamp head. Each of these trunk elements <NUM> and <NUM> may extend longitudinally between and to the opposing trunk ends <NUM> and <NUM>.

The trunk base <NUM> is arranged at (e.g., on, adjacent or proximate) the trunk top side <NUM>. The trunk base <NUM> of <FIG>, for example, extends vertically from the trunk top side <NUM> towards the trunk bottom side <NUM>. This trunk base <NUM> extends laterally between and to the opposing trunk sides <NUM> and <NUM>. At least a portion <NUM> (or an entirety) of the trunk base <NUM> may be laterally tapered. The trunk portion <NUM> of <FIG>, for example, laterally tapers as the trunk base <NUM> extends vertically to the trunk top side <NUM>. This tapered configuration provides the trunk base <NUM> with a canted exterior surface <NUM> extending along the trunk second side <NUM>. This second side surface <NUM> is angularly offset from an exterior surface <NUM> of the trunk <NUM> extending along the trunk top side <NUM> by an included angle; e.g., an obtuse angle. The second side surface <NUM> is angularly offset from an exterior surface <NUM> of the trunk <NUM> extending along the trunk first side <NUM> by an included angle; e.g., an acute angle. The first side surface <NUM>, by contrast, may be configured perpendicular to the top side surface <NUM>.

The trunk protrusion <NUM> is arranged at (e.g., on, adjacent or proximate) the trunk bottom side <NUM>. The trunk protrusion <NUM> of <FIG>, for example, projects vertically out from the trunk base <NUM> to the trunk bottom side <NUM>. The trunk protrusion <NUM> is arranged at (e.g., on, adjacent or proximate) the trunk second side <NUM>. The trunk protrusion <NUM> of <FIG>, for example, projects laterally from the trunk second side <NUM> to a side <NUM> of the trunk protrusion <NUM> which is laterally displaced from the trunk first side <NUM>.

Each trunk <NUM> may be constructed from a non-electrically conductive material. This non-electrically conductive material may be a polymer such as, but not limited to, polyurethane. The present disclosure, however, is not limited to the foregoing exemplary trunk materials.

Referring to <FIG>, the trunks <NUM> are arranged within the inter-beam channel <NUM>. Referring to <FIG>, each of the frame beams <NUM> is configured with a set (e.g., a row) of one or more of the trunks <NUM>. Each set of the trunks <NUM>, for example, may be arranged end-to-end longitudinally along a respective one of the frame beams <NUM>, where the trunk first sides <NUM> laterally engage (e.g., contact, abut) the respective frame beam <NUM>; see <FIG>.

Referring to <FIG>, each of the trunks <NUM> is connected to the respective frame beam <NUM> in a repositionable manner. For example, each trunk <NUM> of <FIG> is secured to the respective frame beam <NUM> by a quick release coupler <NUM> and one or more fastener assemblies <NUM>; e.g., bolt and nut assemblies. Each of these connectors <NUM> and <NUM> may be mated with a respective aperture (e.g., slot) in a web of the frame beam <NUM>, which aperture is sized to facilitate vertical (e.g., up and down) movement of the trunk <NUM> along the respective frame beam <NUM> and its web. The quick release coupler <NUM> is configured to temporarily maintain a vertical position of the respective trunk <NUM> along the respective frame beam <NUM> while the fastener assemblies <NUM> are loose. The fastener assemblies <NUM> are configured to fix the vertical position of the respective trunk <NUM> for the induction welding of the workpiece <NUM> (see <FIG>). Each of the fastener assemblies <NUM>, for example, may be tightened to clamp the respective trunk <NUM> laterally against the respective frame beam <NUM> and its web and thereby fix the vertical position of the trunk <NUM>.

Referring to <FIG>, the top heat sink <NUM> is configured as a component operable to absorb heat energy. The top heat sink <NUM>, for example, may be constructed from a ceramic such as, but not limited to, aluminum silicate (also referred to as alumina silicate). The present disclosure, however, is not limited to the foregoing exemplary top heat sink materials.

The top heat sink <NUM> of <FIG> extends longitudinally between and to a first end <NUM> of the top heat sink <NUM> and a second end <NUM> of the top heat sink <NUM>. The top heat sink <NUM> extends laterally between and to a first side <NUM> of the top heat sink <NUM> and a second side <NUM> of the top heat sink <NUM>. The top heat sink <NUM> extends vertically between and to a bottom side <NUM> of the top heat sink <NUM> and a top side <NUM> of the top heat sink <NUM>.

The top heat sink <NUM> may be laterally tapered. The top heat sink <NUM> of <FIG>, for example, laterally tapers as the top heat sink <NUM> extends vertically from the heat sink top side <NUM> to the heat sink bottom side <NUM>. The top heat sink <NUM> of <FIG>, for example, has a (e.g., isosceles) trapezoidal cross-sectional geometry when viewed, for example, in a plane perpendicular to the longitudinal x-axis. The present disclosure, however, is not limited to such an exemplary second heat sink configuration.

Referring to <FIG>, the heat sink holder <NUM> extends longitudinally between and to a first end <NUM> of the heat sink holder <NUM> and a second end <NUM> of the heat sink holder <NUM>. The heat sink holder <NUM> extends laterally between and to a first side <NUM> of the heat sink holder <NUM> and a second side <NUM> of the heat sink holder <NUM>. The heat sink holder <NUM> extends vertically between and to a bottom side <NUM> of the heat sink holder <NUM> and a top side <NUM> of the heat sink holder <NUM>.

The heat sink holder <NUM> of <FIG> is configured with a trunk recess <NUM> and a heat sink receptacle <NUM>. Each of these holder apertures <NUM> and <NUM> may extend longitudinally through (or within) the heat sink holder <NUM> between the opposing ends <NUM> and <NUM>.

The trunk recess <NUM> is arranged at (e.g., on, adjacent or proximate) the holder top side <NUM>, and intermediate (e.g., midway) laterally between the opposing holder sides <NUM> and <NUM>. The trunk recess <NUM> of <FIG>, for example, extends vertically into the heat sink holder <NUM> from the holder top side <NUM> to a recess end surface <NUM> of the heat sink holder <NUM>. The trunk recess <NUM> extends laterally within the heat sink holder <NUM> between and to opposing recess side surfaces 182A and 182B (generally referred to as "<NUM>") of the heat sink holder <NUM>. In some embodiments, the opposing recess side surfaces <NUM> may have an arcuate cross-sectional geometry when viewed, for example, in a plane perpendicular to the longitudinal x-axis.

The heat sink receptacle <NUM> is located at (e.g., on, adjacent or proximate) the holder bottom side <NUM>, and intermediate (e.g., midway) laterally between the opposing holder sides <NUM> and <NUM> and the opposing recess side surfaces <NUM>. The heat sink receptacle <NUM> of <FIG>, for example, extends vertically into the heat sink holder <NUM> from the recess end surface <NUM> to the holder bottom side <NUM>. The heat sink receptacle <NUM> extends laterally within the heat sink holder <NUM> between and to opposing receptacle side surfaces 184A and 184B (generally referred to as "<NUM>") of the heat sink holder <NUM>. Each of these receptacle side surfaces <NUM> may be a canted surface. Each of the receptacle side surfaces <NUM>, for example, may be angularly offset from a surface <NUM> extending along the holder bottom side <NUM> by an included angle; e.g., an acute angle. The heat sink receptacle <NUM> may thereby have, for example, a (e.g., isosceles) trapezoidal cross-sectional geometry when viewed, for example, in a plane perpendicular to the longitudinal x-axis. This trapezoidal cross-sectional geometry may be similar to the trapezoidal cross-sectional geometry of the top heat sink <NUM> of <FIG> in shape, but may be slightly larger in size as shown in <FIG>.

The heat sink holder <NUM> may be constructed from a non-electrically conductive material. This non-electrically conductive material may be a polymer such as, but not limited to, polyurethane. The present disclosure, however, is not limited to the foregoing exemplary heat sink holder materials.

Referring to <FIG>, the heat sink holder <NUM> is connected to the support structure frame <NUM> at the frame bottom side <NUM>. The heat sink holder <NUM>, for example, is connected (e.g., mechanically fastened, bonded and/or otherwise attached) to flanges of the frame beams <NUM> at the frame bottom side <NUM>.

The top heat sink <NUM> is mated with (e.g., received within) the heat sink receptacle <NUM> (see <FIG>). The receptacle side surfaces <NUM> laterally overlap end portions of the top heat sink <NUM>. The receptacle side surfaces <NUM> may thereby locate and vertically support the top heat sink <NUM> in its mated position. The trunks <NUM> may also be vertically positioned such that their projections <NUM> vertically engage (e.g., contact) and/or abut against the heat sink top side <NUM>. The trunks <NUM> may thereby retain the top heat sink <NUM> within the heat sink receptacle <NUM> (see <FIG>). The trunks <NUM> also provide a support (e.g., a backstop) for the top heat sink <NUM> during induction welding as described below in further detail.

Referring to <FIG>, the bottom support structure <NUM> may be mounted on a (e.g., fixed, stationary) base structure <NUM>; e.g., a mounting block. The base structure <NUM> of <FIG> is configured to vertically elevate the bottom support structure <NUM> off of a floor <NUM>; e.g., a metal plate or pan. The base structure <NUM> is also configured to provide mounting areas for fixture accessories <NUM> such as, but not limited to, valving and/or gauges for controlling and/or monitoring the actuator <NUM>. Note, connections (e.g., conduits) between the elements <NUM> and <NUM> are omitted for clarity of illustration.

The top support structure <NUM> may be configured as part of a gantry <NUM>. The gantry <NUM> of <FIG> is configured to move laterally (e.g., along the y-axis) along one or more tracks <NUM> (e.g., rails), which tracks <NUM> are disposed on opposing lateral sides of the base structure <NUM> and connected to the floor <NUM>. The gantry <NUM> of <FIG> includes one or more vertical supports 198A and 198B (generally referred to as "<NUM>"); e.g., side frames. The top support structure <NUM> is vertically displaced from (e.g., positioned vertically above) the bottom support structure <NUM>. The top support structure <NUM> is arranged longitudinally between and connected to the vertical supports <NUM>. The top support structure <NUM> of <FIG> is configured to move vertically (e.g., along the z-axis) along one or more tracks <NUM> (e.g., rails), which tracks <NUM> are respectively connected to and extend vertically along the vertical supports <NUM>. One or more actuators (e.g., hydraulic cylinders) may be configured to move the top support structure <NUM> along the tracks <NUM>. One or more actuators (e.g., hydraulic cylinders) may also or alternatively be configured to move the gantry <NUM> along the tracks <NUM>. Of course, in other embodiments, the top support structure <NUM> and/or the gantry <NUM> may be manually moveable.

<FIG> is a flow diagram of a method <NUM> for induction welding a workpiece; e.g., the workpiece <NUM>. This method <NUM> may be performed using an induction welding system such as, but not limited to, the induction welding system <NUM> of <FIG>.

In step <NUM>, the induction welding fixture <NUM> and the workpiece <NUM> are arranged together. The workpiece <NUM> and its members <NUM>, for example, may be arranged vertically between the bottom support structure <NUM> and the top support structure <NUM>. For example, referring to <FIG>, the workpiece <NUM> may be arranged within the workpiece receptacle <NUM>. A portion of the first workpiece member 28A may laterally and longitudinally overlap (e.g., lap) a portion of the second workpiece member 28B. One or more workpiece shims <NUM> and <NUM> may be provided to support the workpiece members <NUM>, which workpiece shims <NUM> and <NUM> may be constructed from a composite material such as fiberglass embedded within an epoxy matrix. Each of these shims <NUM> and <NUM> may be arranged within the workpiece receptacle <NUM> with the workpiece <NUM>. The bottom shim <NUM> of <FIG>, for example, is located laterally adjacent (e.g., abutted against) a lateral edge of the first workpiece member 28A. This bottom shim <NUM> is located vertically between and engages (e.g., contacts) the receptacle end surface <NUM> and the second workpiece member 28B. The top shim <NUM> of <FIG> is located laterally adjacent (e.g., abutted against) a lateral edge of the second workpiece member 28B. This top shim <NUM> is located vertically on a (e.g., top) surface <NUM> of the first workpiece member 28A.

In step <NUM>, the workpiece <NUM> is secured vertically between the bottom support structure <NUM> and the top support structure <NUM>. The top support structure <NUM> of <FIG>, for example, may be moved along the tracks <NUM> until the top support structure <NUM> engages (e.g., contacts) one or more of the elements <NUM>, 28B, <NUM>; e.g., see <FIG> and <FIG>. The heat sink holder <NUM> of <FIG>, for example, may vertically contact a top surface <NUM> of the support structure base <NUM> at its top end <NUM>. Referring to <FIG>, the heat sink holder <NUM> may vertically contact a top surface <NUM> of the second workpiece member 28B and a top surface <NUM> of the top shim <NUM>. A bottom workpiece contact surface <NUM> of the top heat sink <NUM> may abut vertically against and contact the second workpiece member surface <NUM> and/or the second shim surface <NUM>. The top heat sink <NUM> may thereby engage a top side of the workpiece <NUM> and its top surface <NUM>.

The trunks <NUM> may be adjusted vertically such that the trunk protrusions <NUM> engage (e.g., contact) a top surface <NUM> of the top heat sink <NUM>, which surface <NUM> is vertically opposite the heat sink surface <NUM>. The trunks <NUM> may thereby provide a backstop for the top heat sink <NUM> as well as retain the top heat sink <NUM> against the workpiece <NUM> and its members <NUM>.

The actuator <NUM> may be actuated (e.g., inflated) to move (e.g., push) the elements <NUM> and <NUM> vertically upwards within the base channel <NUM> towards the workpiece <NUM>. This movement may cause the bottom heat management device <NUM> to vertically engage (e.g., contact) at least the workpiece <NUM> at a bottom side thereof. More particularly, a top workpiece contact surface <NUM> of the bottom heat management device <NUM> may abut vertically against and contact a bottom surface <NUM> of the first workpiece member 28A. The actuator <NUM> may be actuated further such that the workpiece <NUM> and its overlapping members <NUM> are pressed (e.g., clamped) vertically between the support structures <NUM> and <NUM> and their heat sinks <NUM> and <NUM>. The workpiece <NUM> and its members <NUM> may thereby be secured (e.g., clamped) vertically between the support structures <NUM> and <NUM> and, more particularly, the heat sinks <NUM> and <NUM> using the trunks <NUM> as a backstop / anchor for the top heat sink <NUM>.

In step <NUM>, the workpiece <NUM> is induction welded. The induction welding coil <NUM>, for example, may be arranged in the channel <NUM> between the trunks <NUM> such that the welding segment <NUM> is parallel with and slightly elevated from the heat sink surface <NUM>. Once in position, the power source <NUM> (see <FIG>) may provide a high frequency (e.g., alternating) current to the induction welding coil <NUM>. The induction welding coil <NUM> may subsequently generate electromagnetic waves which excite one or more reinforcement fibers within the first workpiece member 28A via eddy currents and/or one or more of reinforcement fibers within the second workpiece member 28B via eddy currents. This excitation may elevate a temperature of the first workpiece member 28A and/or the second workpiece member 28B to a melting point temperature where a polymer (e.g., thermoplastic) matrix of the first workpiece member 28A and/or a polymer (e.g., thermoplastic) matrix of the second workpiece member 28B melts. Referring to <FIG>, a melt layer may form at an interface <NUM> (e.g., a weld joint / seam) between the first workpiece member 28A and the second workpiece member 28B. This melt layer may bond the first workpiece member 28A and the second workpiece member 28B together upon cooling thereof.

The induction welding coil <NUM> may be moved longitudinally (e.g., in the y-axis direction) to provide an elongated welded seam between the first workpiece member 28A and the second workpiece member 28B. As the induction welding coil <NUM> moves longitudinally, the induction welding coil <NUM> translates laterally within the channel <NUM> along the trunks <NUM> on either side thereof.

By securing the workpiece <NUM> between the support structures <NUM> and <NUM> and their heat sinks <NUM> and <NUM> during the induction welding, the induction welding fixture <NUM> may maintain contact between the workpiece members <NUM> being welded together. The induction welding fixture <NUM> may also maintain a compressive force across the overlap joint between the workpiece members <NUM> to facilitate improved fusion. The heat sinks <NUM> and <NUM> may also or alternatively provide uniform heat for welding at the interface <NUM>.

In step <NUM>, the workpiece <NUM> is released from the induction welding fixture <NUM>. The actuator <NUM> of <FIG>, for example, may be actuated (e.g., deflated) such that the bottom heat management device <NUM> moves (e.g., inwards) away from the workpiece <NUM>. The top support structure <NUM> may then be moved vertically (e.g., upwards) away from the workpiece <NUM>. The now fused workpiece <NUM> may subsequently be removed from the induction welding fixture <NUM>. Alternatively, the induction welding fixture <NUM> and the workpiece <NUM> may be rearranged to induction weld the workpiece <NUM> at another location; e.g., another location laterally along the workpiece <NUM>. The steps <NUM>, <NUM> and <NUM> may be repeated at this other location to further induction weld the workpiece <NUM>. For example, the first and the second workpiece members <NUM> may be welded together again at the other location to provide another weld seam. Alternatively, one or more other members <NUM> of the workpiece <NUM> may alternatively be induction welded together.

To accommodate induction welding of the workpiece <NUM> at multiple locations and/or induction welding workpieces <NUM> with various different configurations, the induction welding fixture <NUM> of the present disclosure is configured with multiple adjustable components. For example, the top support structure <NUM> may be moved laterally (e.g., via the gantry <NUM>) and/or vertically to facilitate placement of the workpiece <NUM> with the induction welding fixture <NUM>. The top support structure <NUM> may also or alternatively be moved to accommodate different workpiece thicknesses. The trunks <NUM> may be adjusted vertically for adjusting the backstop position of the top heat sink <NUM>. The trunks <NUM> may also be adjusted vertically for removal and replacement of the top heat sink <NUM>. One or more of the trunks <NUM> may also be swapped out (e.g., exchanged) for replacement trunks <NUM>. By replacing the top heat sink <NUM> and/or the trunks <NUM>, the induction welding fixture <NUM> may accommodate workpieces with different surface geometries (e.g., planar, curved or otherwise) along the overlap joint or the same workpiece with different surface geometries at different weld locations. For example, referring to <FIG>, where the exterior surface <NUM> of the workpiece <NUM> is planar (e.g., flat), a bottom (e.g., heat sink engagement) surface <NUM> of each trunk protrusion <NUM> and/or the heat sink surface <NUM>, <NUM> may also be planar. Referring to <FIG>, where the exterior surface <NUM> of the workpiece <NUM> is curved, one or more of the trunk protrusions surfaces <NUM> and/or the heat sink surface <NUM>, <NUM> may also be curved. Similarly, the bottom heat management device <NUM> and/or the workpiece shims <NUM> and <NUM> may be replaced depending upon the specific geometry of the workpiece <NUM> to be induction welded. In addition or alternatively, the support structure base <NUM> may also or alternatively be replaced in order to accommodate induction welding of workpieces with different configurations.

The method is described above as the induction welding fixture <NUM> being stationary and the workpiece <NUM> being moveable to adjust the position of the workpiece <NUM> relative to the induction welding fixture <NUM>. However, in other embodiments, the workpiece <NUM> may be stationary and the induction welding fixture <NUM> may be moveable to adjust the position of the induction welding fixture <NUM> relative to the workpiece <NUM>. In still other embodiments, both the induction welding fixture <NUM> and the workpiece <NUM> may be moveable for increasing adjustment options.

In some embodiments, the induction welding fixture <NUM> may have a generally rectangular configuration as shown in <FIG> (see also <FIG>). In other embodiments, the induction welding fixture <NUM> may have a non-rectangular configuration as shown in <FIG>. The induction welding fixture <NUM> of <FIG>, for example, may be particularly suited for induction welding curved (e.g., arcuate) workpieces. The beams <NUM> and/or the base <NUM>, for example, may be curved or include curved portions.

The method <NUM> and the induction welding system <NUM> of the present disclosure may be utilized for induction welding various different types and configurations of workpieces <NUM>. For example, the workpiece <NUM> may be configured as a fan cowl for a nacelle of an aircraft propulsion system. The workpiece <NUM>, however, may alternatively be configured as or may otherwise be included as part of another nacelle component, an aircraft control surface, a wing or an aircraft fuselage. The present disclosure, however, is not limited to induction welding and manufacturing such exemplary components or to aircraft propulsion system applications. For example, the method <NUM> and the induction welding system <NUM> may be utilized for manufacturing any type or configuration of workpiece where two or more bodies (e.g., workpiece members <NUM>) are joined together via induction welding.

In some embodiments, referring to <FIG>, the workpiece members <NUM> may be configured as planar or non-planar (e.g., curved) sheets of material. In other embodiments, referring to <FIG>, any one or more of the workpiece members <NUM> (e.g., 28B) may be configured with more complex (e.g., convoluted, bent, etc.) geometry. The workpiece member 28B of <FIG>, for example, is configured with an L-shaped cross-sectional geometry, for example, to provide the workpiece with a flange. The workpiece member 28B of <FIG> is configured with a channeled (e.g., top-hat shaped) geometry, for example, to provide the workpiece <NUM> with a stiffener, a mount and/or a channel. The present disclosure, however, is not limited to the foregoing exemplary workpiece member configurations.

In some embodiments, referring to <FIG>, the bottom support structure <NUM> may be configured as a mobile unit. The base structure <NUM> of <FIG>, for example, includes one or more wheels <NUM>. These wheels <NUM> are connected to the base structure <NUM> at a bottom surface <NUM> of the base structure <NUM>. The wheels <NUM> may be operable to move freely on the floor <NUM>. Alternatively, the wheels <NUM> may run on one or more tracks <NUM>. With such an arrangement, the bottom support structure <NUM> may be moved within / into or out of a gentry tunnel <NUM> to provide additional adjustment and/or facilitate placement and/or removal of the workpiece (not shown in <FIG>).

In some embodiments, the induction welding fixture <NUM> may include a plurality of the top support structures <NUM> (schematically shown in <FIG>). Each of these top support structures <NUM> may be arranged with a respective gantry <NUM>, where each gantry <NUM> may be fixed to the floor <NUM>. With this arrangement, the top support structures <NUM> may be configured with different trunks <NUM> (see <FIG>). The top support structures <NUM>, for example, may be setup to align with respective portions of the workpiece (not shown in <FIG>) with different geometries. A larger portion or an entirety of the workpiece may thereby be induction welded without requiring readjustment of a single top support structure <NUM>. In addition or alternatively, different locations on the workpiece may be induction welded concurrently; e.g., simultaneously.

While the multiple gantries <NUM> shown in <FIG> are configured as fixed gantries, it is contemplated that one or more of these gantries <NUM> may alternatively be mobile. Each of the gantries <NUM> in <FIG>, for example, may alternatively be configured to move along tracks <NUM> as shown, for example, in <FIG>. Each gantry <NUM> and its respective top support structure <NUM> may thereby move relative to the bottom support structure <NUM> and/or relative to the other gantry <NUM> and its respective top support structure <NUM>.

<FIG> illustrates the induction welding fixture <NUM> with two gantries <NUM> and two respective top support structures <NUM>. It is contemplated, however, the induction welding fixture <NUM> may include three or more gantries <NUM> and/or three or more top support structures <NUM>. Furthermore, while the induction welding fixture <NUM> is illustrated with a single base structure <NUM> and a single bottom support structure <NUM>, the present disclosure is not limited to such exemplarily configurations. For example, in addition to or alternatively to including more than one gantry <NUM> / more than one top support structure <NUM>, the induction welding fixture <NUM> may also include two or more base structures <NUM> and/or two or more bottom support structures <NUM>.

Claim 1:
An assembly for induction welding, comprising:
a fixture (<NUM>) including a first support structure (<NUM>), a second support structure (<NUM>) and a third support structure;
the second support structure (<NUM>) including a frame (<NUM>) and a plurality of trunks (<NUM>), each of the plurality of trunks (<NUM>) connected to and repositionable on the frame (<NUM>);
the third support structure including a second frame and a plurality of second trunks, and each of the plurality of second trunks connected to and repositionable on the second frame;
the fixture (<NUM>) configured to secure a workpiece (<NUM>) vertically between the first support structure (<NUM>) and the second support structure (<NUM>) using the plurality of trunks (<NUM>) during induction welding of the workpiece (<NUM>); and
the fixture (<NUM>) further configured to secure the workpiece (<NUM>) with the third support structure using the plurality of second trunks during the induction welding of the workpiece (<NUM>),
wherein each of the plurality of trunks (<NUM>) and each of the plurality of second trunks is configured as a support block.