Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
  • B23K13/00—Welding by high-frequency current heating
  • B23K13/01—Welding by high-frequency current heating by induction heating
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
  • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
  • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
  • B29C65/36—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction
  • B29C65/3604—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the type of elements heated by induction which remain in the joint
  • B29C65/3636—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the type of elements heated by induction which remain in the joint comprising independent continuous fibre-reinforcements
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
  • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
  • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
  • B29C65/36—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction
  • B29C65/3672—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the composition of the elements heated by induction which remain in the joint
  • B29C65/3676—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the composition of the elements heated by induction which remain in the joint being metallic
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
  • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
  • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
  • B29C65/36—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction
  • B29C65/3672—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the composition of the elements heated by induction which remain in the joint
  • B29C65/3684—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the composition of the elements heated by induction which remain in the joint being non-metallic
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/01—General aspects dealing with the joint area or with the area to be joined
  • B29C66/05—Particular design of joint configurations
  • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
  • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
  • B29C66/112—Single lapped joints
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/01—General aspects dealing with the joint area or with the area to be joined
  • B29C66/05—Particular design of joint configurations
  • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
  • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
  • B29C66/112—Single lapped joints
  • B29C66/1122—Single lap to lap joints, i.e. overlap joints
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/01—General aspects dealing with the joint area or with the area to be joined
  • B29C66/05—Particular design of joint configurations
  • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
  • B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
  • B29C66/131—Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/01—General aspects dealing with the joint area or with the area to be joined
  • B29C66/347—General aspects dealing with the joint area or with the area to be joined using particular temperature distributions or gradients; using particular heat distributions or gradients
  • B29C66/3474—General aspects dealing with the joint area or with the area to be joined using particular temperature distributions or gradients; using particular heat distributions or gradients perpendicular to the plane of the joint
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
  • B29C66/47—Joining single elements to sheets, plates or other substantially flat surfaces
  • B29C66/474—Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially non-flat
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
  • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
  • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
  • B29C66/532—Joining single elements to the wall of tubular articles, hollow articles or bars
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
  • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
  • B29C66/721—Fibre-reinforced materials
  • B29C66/7212—Fibre-reinforced materials characterised by the composition of the fibres
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
  • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
  • B29C66/721—Fibre-reinforced materials
  • B29C66/7214—Fibre-reinforced materials characterised by the length of the fibres
  • B29C66/72141—Fibres of continuous length
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
  • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
  • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
  • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
  • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/80—General aspects of machine operations or constructions and parts thereof
  • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
  • B29C66/836—Moving relative to and tangentially to the parts to be joined, e.g. transversely to the displacement of the parts to be joined, e.g. using a X-Y table
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
  • B23K2103/00—Materials to be soldered, welded or cut
  • B23K2103/16—Composite materials, e.g. fibre reinforced
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
  • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
  • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
  • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
  • B29C2035/0811—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using induction
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/01—General aspects dealing with the joint area or with the area to be joined
  • B29C66/347—General aspects dealing with the joint area or with the area to be joined using particular temperature distributions or gradients; using particular heat distributions or gradients
  • B29C66/3472—General aspects dealing with the joint area or with the area to be joined using particular temperature distributions or gradients; using particular heat distributions or gradients in the plane of the joint, e.g. along the joint line in the plane of the joint or perpendicular to the joint line in the plane of the joint
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C66/00—General aspects of processes or apparatus for joining preformed parts
  • B29C66/90—Measuring or controlling the joining process
  • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
  • B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
  • B29L2031/00—Other particular articles
  • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
  • B29L2031/3055—Cars
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
  • B29L2031/00—Other particular articles
  • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
  • B29L2031/3076—Aircrafts

Definitions

• the present invention relates to an installation for dynamic welding, preferably without contact, by induction of two parts made of composite material comprising a thermoplastic polymer material.
• the invention also relates to a welding process using this installation.
• This installation and this method can be implemented in the context of the welding of parts, in particular of large dimensions, intended for the aeronautical sector, but also for the automotive sector, wind power and any other industrial sector.
• Another technique which consists in placing the parts in an autoclave for several hours, for example 8 hours, in order to consolidate them by melting their matrix in order to assemble the parts together.
• this technique increases the processing time, the energy required for its implementation, and is not easy to implement for large parts.
• thermoplastic polymer matrix are increasingly used in industrial fields, in particular for their advantageous mechanical properties.
• LSP lightning protection system
• the targeting of the induction heating on the interface between the two parts is further complicated. Indeed, the inductor generates overheating of the lightning protection system, while not allowing the interface between the parts to reach a sufficient temperature for heating.
• US2020223153 describes a method for joining overlapping thermoplastic membrane components using an electrically conductive metal susceptor.
• DE 102008044208 presents a device for welding two components between which a plastic material is partially introduced.
• a dynamic induction welding installation for welding a first and a second part together in a weld zone, the second part being arranged between a lightning protection system and the first part, the first and second parts each comprising a composite material comprising reinforcing fibers and a thermoplastic polymer matrix, the installation comprising:
• an induction heating device arranged on one side of the first part which is opposite to the second part and configured to create a magnetic field so as to produce the weld in the weld zone
• a support arranged in contact with the lightning protection system on one side of the latter which is opposite to the second part, the support being configured in such a way as to make it possible to create a magnetic reaction field opposing at least partially to the magnetic field created by the induction heater in at least part of the lightning protection system.
• the induction heating device creates a variable magnetic field passing through, at least in part, the first part, the second part and the lightning protection system, at the level of the welding zone, that is to say in the environment of the weld zone, in particular above and below the latter, along an axis perpendicular to the longitudinal axis of the first part and crossing the first part, the second part, the lightning protection system and the support, this axis possibly corresponding to a vertical axis.
• variable magnetic field leads to the formation of variable induced currents in the reinforcing fibers which then heat up by the Joule effect.
• the heat from the reinforcing fibers is then transferred to the matrix which in turn heats until fusion so as to allow welding at the interface between the parts.
• welding retains the mechanical properties of the first part.
• variable magnetic field also leads to the formation of variable induced currents in the lightning protection system which will then heat up by the Joule effect.
• the formation of induced currents in at least part of the lightning protection system is at least partially canceled, preferably canceled by at least 50%, better canceled by at least 70%, even better canceled by at least 90%.
• the Joule effect in at least part of the lightning protection system is limited, which reduces the temperature rise of the latter.
• the magnetic reaction field of the support is advantageously created passively, that is to say without additional energy input, in reaction to the magnetic field of the induction heating device.
• the support comprises at least one active layer, configured in such a way as to make it possible to create the reaction magnetic field at least partially opposing the magnetic field created by the induction heating device in at least part of the lightning protection system .
• said active layer does not contribute to the supply of heat allowing the welding to be carried out.
• the support preferably comprises several layers of materials superimposed on each other at least partially, in particular at least one layer of thermal insulation and said at least one active layer.
• the support comprises in a particular embodiment, at least three layers, for example exactly three layers, including said at least one active layer sandwiched between two layers of thermal insulation.
• Said at least one layer of thermal insulation can be made of a non-magnetic and electrically non-conductive material, for example a composite material based on glass fibers of the E60 or E70 type, preferably being machinable.
• At least one thermal insulation layer of the support may be in contact with the lightning protection system.
• This layer of thermal insulation can have a thickness of between 0.1 mm and 3 mm.
• Said at least one layer of thermal insulation can make it possible to ensure good contact between the support and the lightning protection system and can make it possible to take up mechanical forces, in particular pressure, applied to said parts during the welding of those -this.
• Said at least one layer of thermal insulation is preferably resistant to mechanical stresses and resistant to thermal fields.
• Said at least one active layer may have a thickness of between 1 and
• the support in particular the active layer, may comprise a material having a relative magnetic permeability of between 1 and 1000.
• the support in particular the active layer, may comprise a material having an electrical conductivity of between 10 6 and 10 8 Sm 1 .
• the magnetic field of the induction heating device promotes the creation of induced currents called eddy currents in the support, in particular in the active layer. These currents then produce the reaction magnetic field whose direction is opposite to the magnetic field created by the induction heater.
• the support in particular the active layer, may comprise a material chosen from the family of metals, in particular copper, steel, in particular stainless steel, magnetic or non-magnetic, bronze or a metal alloy comprising one or more of such metals.
• a support material is advantageously chosen to obtain an electrical conductivity adapted to the nature of the lightning protection system, that is to say its composition or its shape.
• the support can form a mono- or multi-layer mattress, preferably multi-layer, having a total thickness of between 5 mm and 500 mm.
• the support advantageously has a width and a length greater than or equal to those of the weld zone, the width and the length of the support preferably being at least equal to those of the lightning protection system.
• the mattress forming the support may consist of a plate extending substantially parallel to at least part of the second part.
• the first part and the second part can comprise the same reinforcing fibers and/or the same thermoplastic polymer matrix.
• the reinforcing fibers of the first and second parts can be continuous fibers. They are advantageously chosen from the group consisting of carbon fibers and metal fibers.
• thermoplastic polymer of the matrix can be chosen from the group consisting of the family of polyaryletherketones (PAEK), in particular polyetheretherketone (PEEK) or polyetherketoneketone (PEKK).
• PAEK polyaryletherketones
• PEEK polyetheretherketone
• PEKK polyetherketoneketone
• the first part may consist of a stiffener.
• the first part may have an L-shape in cross section comprising a core and a flange to be welded to the second part, the core and the flange being connected by a bent portion at an angle of between 60° and 120°, in particular between 75° and 105°, preferably equal to approximately 90°.
• the installation may include a punch arranged to support the core at least during welding. Such a punch can be in contact with the core over at least part of the height of the latter, or even over the entire height thereof, on a side of the core which is opposite to that which makes facing the induction heater.
• the lightning protection system can be made of at least one conductive material, in particular copper, bronze or aluminum, and preferably forms a mesh with a thickness of between 0.1 mm and 0.2 mm.
• the lightning protection system can be arranged in contact with the second part, preferably over its entire surface, parallel to the latter, and in contact with the support, in particular in contact with at least one layer of thermal insulation of the support.
• the second part can form a skin with a thickness of between 1,400 ⁇ m and 10,000 ⁇ m and can have, on the side of the first part, a face, in particular flat, to be welded, forming at least partially the weld zone.
• the induction heater can operate with alternating currents up to 2000 A and frequencies below 500 kHz.
• the heating device can be chosen from among the inductors marketed by the company Fives Celes, or by the company CEIA or even by the company EFD.
• Another subject of the invention is a process for the dynamic welding by induction of a first and a second part to one another, the second part being placed between the first part and a lightning protection system, the method being implemented using an installation as defined previously and comprising the steps consisting of:
• the power of the induction heating device being adapted to allow the reaction magnetic field created by the support to compensate for the magnetic field in at least part of the lightning protection system, in particular located at the weld zone.
• the power of the induction heating device is preferably less than 12 kW. In the present invention, the power required to weld said parts is much lower than that required during autoclave welding of the prior art.
• the method may include the preliminary step consisting in predetermining by numerical simulation the parameters of the support, such as the nature of the material and/or its dimensions, in particular its thickness and/or its length, so as to optimize them according to the configuration of the first and second rooms and the lightning protection system.
• the control of the magnetic fields must be very fine and adapted, the objective being to reach the melting temperature of the thermoplastic polymer matrix at the interface between the two parts. Failing this, there is a risk of destroying or at least damaging one of the parts or parts and/or the lightning protection system, at least partially and/or having poor quality or uncontrolled quality welding.
• the reaction magnetic field must attenuate the magnetic field of the heating device in order to limit heating in the lightning protection system without excessively attenuating the magnetic field of the heating device at the level of the weld zone in order to be able to carry out a weld. of good quality.
• the method may include the prior step of predetermining the power of the induction heating device to perform the welding, depending on the support, the nature of the first and second parts and/or the lightning protection system.
• the induction heating device is moved above the weld zone, away from the first part, to make the weld.
• Figure 1 shows in cross section and schematically, an example of a dynamic welding installation according to the invention
• FIG 2 figure 2 represents, in isolation, the support of the installation of figure 1
• FIG 3 shows a block diagram illustrating different steps of an example of a dynamic welding process according to the invention implementing the installation of Figure 1
• FIG 4 is a schematic graph illustrating the heating power in the first and second room and in the lightning protection system when implementing an installation or the method according to the invention
• FIG 5 is a schematic thermal map in the parts made of composite material with a thermoplastic matrix, in the lightning protection system and in the support during the implementation of the method according to the invention,
• FIG 6 figure 6 is an enlargement of detail VI of figure 5,
• FIG 7 is a schematic graph illustrating the heating power in the first and second room and in the lightning protection system with an installation not in accordance with the invention
• FIG 8 is a schematic thermal map in the parts made of composite material with a thermoplastic matrix, in the lightning protection system and in the support during welding with an installation not in accordance with the invention
• Figure 9 is an enlargement of detail IX of Figure 8
• Figure 10 illustrates a final part obtained using the method and installation according to the invention.
• FIG. 1 An installation 1 for dynamic induction welding according to the invention.
• the installation 1 is provided for welding a first part 2 to a second part 3 in a welding zone S located at the interface between the first part 2 and the second part 3.
• the first and second parts 2 and 3 are both made of composite material. They include reinforcing fibers, in this example continuous fibers of carbon, and a thermoplastic polymer matrix, in this example polyetheretherketone (PEEK).
• the first part 2 and the second part 3 are made, still in this example, by stacking plies, also called laminate, in particular with long oriented carbon fibers, with a total thickness between 2 and 3 cm, the first part 2 comprising in this example seven folds and the second part 3 comprising eleven folds.
• the first part 2 is a stiffener, has an L-shaped cross section and extends longitudinally along a longitudinal axis X.
• the first part 2 thus comprises a core 4 and a sole 5, which is the part of the first part 2 which is to be welded to the second part 3.
• the core 4 is connected by a bent portion 17 to the sole 5, the the angle between the core 4 and the sole 5 at the bent portion 17 being in this example equal to approximately 90°.
• the sole 5 is in contact with a face to be welded 6 of the second part 3.
• the thickness of the sole 5 is preferably between 1400 ⁇ m and 3000 ⁇ m, in this example equal to 2000 ⁇ m.
• the second part forms a flat plate, also called a skin, with a thickness preferably between 1,400 ⁇ m and 10,000 ⁇ m, being in this example equal to 5,000 ⁇ m.
• the second part 3 is arranged between the first part 2 and a lightning protection system 15, which in this example comprises a copper mesh with a thickness of 0.1 mm.
• the lightning protection system 15 extends against a surface 7 opposite to the face to be welded 6 of the second part 3, parallel to and in contact with this opposite surface 7.
• the installation 1 comprises an induction heating device 8 which can also be called an inductor, arranged on the side of the first part 2 which is opposite to the second part 3 at a distance from the first part 2, without contact with the latter.
• the induction heating device 8 is thus placed on the side of a free surface 20 of the first part 2, opposite to a face to be welded 21 of the first part 1.
• the faces to be welded 6 and 21 are flat and form the weld zone (S), in the parts where these faces to be welded 6 and 21 are in contact with each other.
• the induction heating device 8 used in the illustrated example is marketed under the name CELES MP12KW by the company Lives Celes.
• This induction heating device 8 is configured to create a magnetic field Bi variable, schematically illustrated in Figure 1, crossing in particular the first part 2, the second part 3 and the lightning protection system 15.
• the induction heater 8 works with alternating currents up to 2000 A and frequencies below 500 kHz.
• the installation 1 also comprises a support 9 on which the lightning protection system 15 is arranged, in contact with the latter on one side which is opposite the second part 3, as can be seen.
• the support 9 thus carries all of the first part 2, the second part 3 and the lightning protection system 15, superimposed in the direction perpendicular to the longitudinal axis X.
• the support 9 is configured in such a way as to make it possible to create a reaction magnetic field B2, illustrated schematically in FIG. 1, at least partially opposing the magnetic field Bi created by the induction heating device 8 in at least one part of the lightning protection system 15.
• the support 9 comprises, in this example, an active layer 26 sandwiched between a first layer of thermal insulation 25 and a second layer of thermal insulation 27.
• the two layers of thermal insulation 25 and 27 are made in this example of composite material with glass fibers of the E60 type.
• the thermal insulation layer 25 of the support 9 is, in this example, in contact with the lightning protection system 15.
• This thermal insulation layer 25 has, in this example, a thickness of 3 mm.
• the active layer 26 has, in this example, a thickness of 1 mm and comprises a metal alloy whose relative magnetic permeability is between 1 and 1000 and whose electrical conductivity is between 10 6 and 10 8 Sm 1 .
• the support 9 forms a mattress extending substantially parallel to the second part 3, has a thickness substantially identical to the thickness of the second part 3, a length and a width greater than those of the weld zone S and approximately equal to those of the lightning protection system 15.
• the material and the dimensions of the support 9 are chosen to make it possible to obtain an electrical conductivity adapted to the nature of the lightning protection system 15, that is to say to its composition and its shape.
• the installation 1 further comprises, in this example, a punch 10 arranged to support the core 4 at least during welding, placed against the core 4 on the side opposite to that which faces the induction heating device 8.
• the method includes a step 31 consisting in positioning the first part 2 against the second part 3, such that the induction heating device 8 is placed on the side of the first part 2 which is opposite the second part 3.
• a magnetic field B i is created using the induction heating device 8 so as to perform a weld at the interface between the first and the second parts 2 and 3.
• the power of the induction heating device 8 is adapted to allow the reaction magnetic field B 2 created by the support 9 to compensate for the magnetic field Bi in at least part of the lightning protection system 15.
• step 32 the induction heating device 8 is moved at a continuous speed, in a direction parallel to the longitudinal axis X of the first part 2, in order to weld the first part 2 and the second part 3 along the entire length of the first part 2.
• the method also includes a preliminary step 29 consisting in predetermining by digital simulation the parameters of the support 9, such as the nature of the material and/or its dimensions, in particular its thickness and/or its length, so as to to optimize them according to the configuration of the first and second parts 2 and 3 and of the lightning protection system 15. It is in fact necessary to adapt the support 9 to the parts to be welded and to the lightning protection system 15 , in particular according to their materials and their shapes which can influence the magnetic field Bi of the induction heating device 8.
• the method may also include a preliminary step 30 consisting in predetermining the power of the induction heating device to perform the welding according to the support 9, the nature of the first and second parts 2 and 3 and the lightning protection system 15 .
• the heating power P transmitted by the installation 1 in the first room 2, the second room 3, the lightning protection system 15 and the support 9 under the induction heating device 8 in a direction orthogonal to the axis longitudinal X and normal to the face to be welded 21 is illustrated in FIG. 4.
• the heating power P in the lightning protection system 15 is relatively low, which greatly limits its heating.
• the temperature in the lightning protection system 15 is less than 100°C.
• the temperature at the level of the weld zone S is greater than 300° C. At this temperature, the thermoplastic matrices of the sole 5 and of the second part 3 are molten at their interface.
• the at least partial opposition of the reaction magnetic field B2, created by the support 9 in the installation 1 according to the invention, to the magnetic field Bi created by the induction heating device 8, makes it possible to at least partially cancel the formation of induced currents in the lightning protection system 15, in this example at least 90%.
• the temperature at this given point will increase when approaching the induction heating device 8, until allowing the thermoplastic polymer matrices of the first and second parts 2 and 3 at this given point to go into a state of fusion.
• the induction heater 8 moves away from the given point in the weld zone S, the temperature decreases until the dies pass into a solid state. They are then merged and therefore welded at the given point.
• the temperature in the lightning protection system 15 during welding does not exceed 100° C. thanks to the formation of the reaction magnetic field B 2 formed by the support 9.
• FIG. 7 a graph illustrating the heating power P under the induction heating device 8 in an installation not in accordance with the invention, that is to say similar to that of the invention but not comprising a support 9 but a support 90 which itself does not make it possible to create a magnetic field of reaction. It is then observed that the heating power P in the lightning protection system 15 under the induction heating device 8 is very high and much higher than the heating power P in the first room 2 or in the second room 3.
• FIGS. 8 and 9 there is illustrated, for such an installation not in accordance with the invention, iso-temperatures at 300° C. T300, at 400° C. T400, at 500° C. T500 and at 700° C. T700 d thermal mapping during welding.
• the induction heating leads to local temperatures in the lightning protection system 15, during welding, which are higher than 700° C. and can reach 800° C. while the temperature near the weld zone S is greater than 300°C. This overheating risks damaging the lightning protection system 15 and the second part 3 and/or not producing an acceptable weld.
• This high temperature observed in the lightning protection system 15 is partly explained by the presence of eddy currents in the lightning protection system 15.
• the punch 10 can be removed from the final part 100 as shown in the figure. 10.
• the final part 100 comprises the first part 2 welded to the second part 3 at the level of the welding zone, as well as the lightning protection system 15 leaning against the second part 3 on the side opposite the first part 2.
• the support can be made of another material, in particular another electrically conductive material or a magnetic material.
• the speed of the induction heating device 8 may be different, in particular variable, or even zero.
• the first part 2 and the second part 3 can have different geometries, thicknesses and/or fibres.
• the first part 2 and the second part 3 can be made differently, in particular in non-laminated composite material, comprise short fibers or comprise particles.

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• Lining Or Joining Of Plastics Or The Like (AREA)

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• 2021
  • 2021-05-25 FR FR2105414A patent/FR3123239B1/fr active Active
• 2022
  • 2022-05-24 WO PCT/EP2022/063992 patent/WO2022248443A1/fr active Application Filing
  • 2022-05-24 EP EP22730242.9A patent/EP4347166A1/de active Pending

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