HEATING ELEMENT, DEVICE, AND METHOD FOR RESISTANCE WELDING OF THERMOPLASTIC COMPONENTS, IN PARTICULAR FOR THE PRODUCTION OF AIRCRAFT, AND AIRCRAFT

Abstract

A heating element for resistance welding of thermoplastic components for aircraft comprises electrically conductive elements in the form of wires or fibers, which heat up upon application of an electric voltage to the heating element, to weld a first component to a second component in a region electrically heated by the heating element. The electrically conductive elements extend parallel to one another between contact regions for electrically contacting the heating element. After the welding procedure, the heating element remains between the welded components to enhance the strength of the welded bond. A device for bonding thermoplastic components by resistance welding comprises the heating element and a unit in the form of roller electrodes for displacing an electrically heated region of the components in the welding direction. The electrically conductive elements extend parallel to the axis of rotation of the roller electrodes.

Claims

1. A heating element for resistance welding of thermoplastic components, comprising: one or more electrically conductive elements, which heat up upon application of an electric voltage to the heating element, to weld a first component to a second component in a region electrically heated by the heating element when placed between the components during a welding procedure, wherein the heating element is configured to remain between the welded components after the welding procedure and forms a reinforcement to enhance a strength of a welded bond therein, and wherein the electrically conductive elements are configured as wires or fibers, which extend parallel to one another between contact regions, for electrically contacting the heating element.

2. A heating element according to claim 1 being configured for a production of aircraft.

3. The heating element according to claim 1, wherein the electrically conductive elements in the heating element are aligned in a direction of a main load, which acts on the first and second components to be welded to one another.

4. The heating element according to claim 1, wherein the electrically conductive elements extend electrically insulated from one another between contact regions of the heating element.

5. The heating element according to claim 1, wherein an orientation of the conductive elements is oriented perpendicular to a direction of a weld seam to be produced.

6. The heating element according to claim 1, wherein at least one contact surface for contacting an electrode is movable in relation to the heating element.

7. A device for bonding thermoplastic components by resistance welding comprising: the heating element according to claim 1, and a unit for displacing an electrically heated region of the components in a welding direction along the components.

8. The device according to claim 7 configured for a production of aircraft.

9. The device according to claim 7, wherein the unit for displacing the electrically heated region comprises one or more contact elements which are movable in relation to the heating element to electrically contact the heating element at different points in succession.

10. The device according to claim 9, wherein the contact elements are configured as roller electrodes which roll on the heating element during the welding procedure to continuously supply various partial regions of the heating element with current in succession.

11. The device according to claim 10, wherein the electrically conductive elements of the heating element extend parallel to an axis of rotation of the roller electrodes.

12. The device according to claim 7, wherein one or more contact pressure elements to press the first component and the second component against one another in a contact pressure region during the welding procedure, wherein the contact pressure region is movable synchronously with the electrically heated region.

13. A method for bonding thermoplastic components by resistance welding, comprising the steps: welding a first component to a second component on an electrically heated region of the components, placing electrically conductive elements of a heating element provided as wires or fibers extending parallel to one another between contact regions for electrically contacting the heating element, and leaving the heating element between the welded components after the welding step to form a reinforcement therein to enhance a strength of a welded bond.

14. The method according to claim 13, wherein the method is used in a production of components for an aircraft.

15. The method according to claim 13, wherein the electrically conductive elements are aligned in a direction of a main load which acts on the components welded to one another.

16. The method according to claim 13, wherein the electrically heated region of the components is moved during the welding step in a welding direction in relation to the components.

17. The method according to claim 13, wherein one electrode is moved in a welding direction and continuously supplies various partial regions of the heating element with current, in which the electrically conductive elements extend electrically insulated from one another and extend perpendicular to the welding direction, in succession.

18. An aircraft comprising components which are provided with a heating element according to claim 1.

19. An aircraft comprising components which were welded using a device according to claim 7.

20. An aircraft comprising components which were produced using a method according to claim 13.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0061] Exemplary embodiments of the invention will be explained in greater detail hereafter on the basis of the appended drawings. In the figures:

[0062] FIG. 1 schematically shows a sectional view of a preferred embodiment of a system according to the invention having the heating element according to the invention, during the production of an overlapping bond in the fuselage region of an airplane;

[0063] FIG. 2 shows a schematic view of a known device for resistance welding;

[0064] FIGS. 3a and 3b schematically show a top view of the preferred embodiment of the invention shown in FIG. 1 during the production of a welded bond of two overlapping components;

[0065] FIG. 4 shows a cross section through a multifunctional heating element according to the invention;

[0066] FIG. 5 shows a flow chart which shows steps of the method according to the invention;

[0067] FIG. 6 shows a side view of a rear fuselage section of a commercial aircraft having longitudinal seams welded according to the invention;

[0068] FIG. 7 shows a sectional view of the fuselage section shown in FIG. 6 having longitudinal seams welded according to the invention;

[0069] FIG. 8 shows a sectional view of a longitudinal seam welded according to the invention of a commercial aircraft.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0070] FIG. 1 shows a sectional view of a system or a device for bonding thermoplastic components of aircraft by means of resistance welding according to one preferred embodiment of the invention. The device or the resistance welding system comprises an electrically conductive heating element 30, which is used to weld a first component 11 to a second component 12 in an electrically heated region of the components.

[0071] The components 11, 12 to be welded contain thermoplastic material and are arranged in an overlapping region on both sides of the heating element 30 for the resistance welding.

[0072] The heating element 30 comprises electrically conductive elements 30a, which are formed as wires and/or fibers, for heating the components 11, 12 upon application of an electric voltage (see also FIGS. 3a and 3b). The heating element 30 is designed so that it remains in the welded bond after the welding procedure and is used permanently therein as a reinforcing element of the components 11, 12 welded to one another.

[0073] The heating element 30 thus fulfils two functions. On the one hand, it is used as a heating element for resistance welding, on the other hand, with its electrically conductive elements 30a, it is used for the structural and/or structural-mechanical reinforcement of the component produced by welding. During the resistance welding, the thermoplastic material is melted, wherein at the bonding point, the thermoplastic material of the components 11, 12 encloses the wires or fibers 30a of the heating element 30 as a matrix, so that a fiber-reinforced bond results.

[0074] The electrically conductive fibers or wires 30a of the heating element 30 are aligned in the main load direction M of the welded bond to be produced (see FIG. 3a). They are embodied as carbon fibers and/or are manufactured from carbon material.

[0075] The heating element 30 is located during the welding procedure between the two components 11, 12, in order to locally heat them by current flow in its electrically conducting elements or fibers 30a. The components 11, 12 to be bonded are, in this example, each a skin section of a fuselage segment and contain thermoplastic material. For the welding, they are arranged adjacent to one another, wherein they are located one on top of the other in an overlap region.

[0076] The heating element 30 is formed planar and extends between the two components 11, 12 to be bonded in a longitudinal direction L or in the X direction, which extends perpendicularly to the plane of the drawing in FIG. 1. The electrically conductive elements 30a or fibers or wires heat up upon application of an electric voltage because of the current flow generated therein (see also FIGS. 3a and 3b).

[0077] Two contact elements in the form of movable electrodes 31, 32 are connected to a voltage source 50 and are used to apply the electric voltage to the heating element 30. The electrodes 31, 32 are designed as movable in relation to the heating element 30. The movement of the electrodes 31, 32 takes place perpendicularly to the plane of the drawing, i.e., in the longitudinal direction L of the heating element 30 (see FIG. 3b).

[0078] The electrodes 31, 32 contact the planar heating element 30 in each case at a contact region 35 or 36, respectively, to generate the current flow between the two electrodes 31, 32 through the heating element 30. The contact regions 35, 36 are located at a left edge region and a right edge region of the heating element 30. The heating current runs exclusively between the opposing electrodes 31, 32 in the direction of the width of the heating element 30, i.e., from left to right or from right to left in FIG. 1.

[0079] The two contact elements formed as movable electrodes 31, 32 form a unit in this manner, which is used to heat a locally delimited partial region of the heating element 30 during the welding procedure and continuously move or displace it along the components 11, 12, while the heating element 30 is located fixed in place between the components 11, 12 to be welded. The unit thus continuously displaces the heated region of the components 11, 12 during the welding procedure along the components 11, 12. The regions of the heating element 30 located outside the locally delimited, displaceable partial region are not supplied with current in this case.

[0080] The region or partial region heated by current flow in the electrically conductive elements 30a forms a welding zone, in which the two components 11, 12 are welded to one another by melting of the thermoplastic material and subsequent solidification with exertion of pressure.

[0081] The movable electrodes 31, 32 are designed as rollers. The rollers or roller electrodes 31, 32 are applied to the heating element 30 during the welding procedure, so that a part of the peripheral surface of each of them forms the contact with the heating element 30 while they roll on the respective contact surface of the heating element 30.

[0082] On the first side or the side located on top in FIG. 1 of the heating element 30, it is electrically contacted by the first electrode 31 in the contact region 35 located on the right in FIG. 1, which is a partial region or edge region of the heating element 30 and extends on the right edge of the heating element 30 on its top side in the longitudinal direction L of the heating element 30 (X direction), i.e., perpendicularly to the plane of the drawing in FIG. 1 (see also FIGS. 3a and 3b).

[0083] On the second side or the side located on the bottom in FIG. 1 of the heating element 30, it is electrically contacted by the second electrode 32 in a contact region 36 located on the left in FIG. 1, which extends on the left edge of the heating element 30 on its bottom side in the longitudinal direction L of the heating element 30.

[0084] The contact points within the contact regions 35, 36 are formed by the respective peripheral surface of the roller-shaped electrodes 31, 32 applied to the heating element 30.

[0085] Due to the rolling of the roller-shaped electrodes 31, 32 on the heating element 30 at the contact regions 35 or 36, respectively, the current-conducting partial region of the heating element 30 between the two electrodes 31, 32 is moved in the longitudinal direction of the heating element 30, which extends perpendicularly to the plane of the drawing of FIG. 1. The electrically heated welding zone, which is heated by the respective current-conducting, locally delimited partial region of the heating element 30, thus continuously progresses in the longitudinal direction (X direction). This movement corresponds to the welding movement W.

[0086] The two components 11, 12 to be bonded to one another are arranged on opposing sides of the heating element 30, i.e., on its top side or bottom side, respectively. The two components 11, 12 are formed by skin sections of a fuselage segment or various fuselage segments. In the present example, a top skin element forms the component 11, while a bottom skin element forms the component 12.

[0087] The two skin sections or components 11, 12 are pressed against one another during the welding procedure in the region of a contact pressure zone with the aid of two opposing contact pressure elements in the form of contact pressure rollers 41, 42. In the example shown here, the contact pressure element 41 arranged above the first component 11 exerts a force oriented downward in the direction of the welding zone on the first or top component 11, while the contact pressure element 42 arranged below the second component 12 exerts an opposing force oriented upward in the direction of the welding zone on the second or bottom component 12.

[0088] In operation, the two contact pressure elements or contact pressure rollers 41, 42 are moved synchronously with the progressing welding zone, so that the two components 11, 12 to be welded to one another are pressed against one another in the respective heated, current-conducting partial region of the heating element 30

[0089] FIGS. 3a and 3b show the resistance welding system or the device having the heating element 30 according to the invention while a welding procedure is carried out in a view from above, which is identified in FIG. 1 by the arrow A.

[0090] The top skin section 11 or the top component 11 overlaps the bottom skin section 12 or the bottom component 12 in an overlap region. The heating element 30 is located between the two skin sections 11, 12 and extends in the longitudinal direction L. The first contact pressure roller 41 is located on the top side of the first skin section or component 11.

[0091] The first or top roller-shaped electrode 31 is located on the right side, adjacent to the top or first contact pressure roller 41. This electrode is in electrical contact with the contact region 35 located underneath of the heating element 30 on its top side.

[0092] The bottom or second electrode 32 is located on the left side adjacent to the bottom or second contact pressure roller 42, which is not visible in FIGS. 3a and 3b. This electrode is in electrical contact with the contact region 36 located above it of the heating element 30 on its bottom side.

[0093] The two electrodes 31, 32 thus contact the heating element 30 on its top side or bottom side, respectively, each on a surface region of the heating element 30 located laterally to the contact pressure zone or the overlap region.

[0094] The two electrodes 31, 32 contact the heating element 30 on the two opposing contact regions 35, 36, respectively, on the respective edge of the heating element 30. The contact regions 35, 36 of the heating element 30 are located laterally adjacent to the overlap region of the components 11, 12. The width of the respective edge or contact region 35, 36 substantially corresponds to the width of the peripheral surface of the respective roller electrode 31 or 32.

[0095] The heating element 30 has a width which is greater than the width of the overlap region of the skin sections or components 11, 12. The contact regions 35, 36 for contacting by the electrodes 31, 32 are thus formed on both sides of the heating element 30.

[0096] To locally bound the heated welding zone in the longitudinal direction L or X direction, i.e., in the direction of the welding movement W, the electrically conductive elements 30a or wires of the heating element 30 extend essentially parallel to one another and electrically insulated from one another in the longitudinal direction L between the contact regions 35, 36 on the two sides of the heating element 30.

[0097] The electrically conductive elements 30a extend parallel to the respective axis of rotation 31a, 32a of the roller electrodes 31, 32 and parallel to the axes of rotation 41a, 41b of the roller-shaped contact pressure elements 41, 42. The current flow between the two roller-shaped electrodes 31, 32 therefore extends through the heating element 30 substantially parallel to the respective axis of rotation 31a, 32a of the roller electrodes 31, 32 and also parallel to the axes of rotation 41a, 41b of the roller-shaped contact pressure elements 41, 42.

[0098] The overlapping fuselage bond of the two skin sections 11, 12 shown in FIGS. 3a and 3b extends in the X direction, which corresponds to the longitudinal direction of the airplane fuselage in the case of a longitudinal seam of the fuselage. The Y direction oriented perpendicular thereto corresponds to the peripheral direction of the fuselage and in this case is the direction of the main load or main load direction M, in which the greatest strain occurs on the seam between the fuselage segments.

[0099] The directions of the fibers 30a arranged in the heating element 30, which are manufactured from electrically conductive material and are provided as carbon fibers, can be selected in accordance with the respective load distribution.

[0100] FIG. 4 shows a sectional view of the multifunctional heating element 30 according to one preferred embodiment, as part of the device according to the invention or the system according to the invention for resistance welding. Insulators 34 are arranged on its top side and bottom side, and between the electrically conductive fibers 30. An adhesive is used in this case which acts as an insulator. The electrically conductive fibers 30a extend in various directions in the heating element 30.

[0101] One electrically conductive terminal element 37, 38, into which the electrically conductive elements or fibers 30a extend at the respective ends thereof, is located at each of the two ends of the heating element 30 located on the right and left in the figure. The elements thus extend beyond the heating surface of the heating element 30, so that the two ends thereof are inserted into the terminal element 37 or 38, respectively, and fixed therein. The terminal elements 37, 38 are manufactured from metal and/or are metal parts, for example. During the welding procedure, they form the contact surfaces 35, 36, on which the electrodes 31, 32 move or on which the electrodes 31, 32 formed as rollers roll.

[0102] The bonding of two components 11, 12, which are skin sections of fuselage segments of an aircraft, according to the present invention is described hereafter by way of example on the basis of FIGS. 1, 3a, 3b, and 5.

[0103] The first skin section 11 is arranged on the second skin section 12 so that the two skin sections overlap in a partial region. The planar heating element 30 is arranged between the two overlapping skin sections 11, 12. It comprises electrically conductive wires or fibers 30a, which are heated during the welding procedure to melt the thermoplastic material of the components 11, 12 in a welding zone, and it is additionally used after the welding procedure as a reinforcing element of the components 11, 12 welded to one another. The wires or fibers 30a of the heating element 30 are manufactured from carbon or are designed as carbon fibers. They are arranged for welding the components 11, 12 in such a way that they are aligned in the direction of the main load M, which acts on the welded bond of the components 11, 12 welded to one another in the installed state. (Step 1).

[0104] To form a welding zone which is locally delimited in a welding direction, the heating element 30 is now supplied with current via movable electrodes 31, 32. This takes place only in a partial region of the heating element 30 locally delimited in the longitudinal direction. This means the heating element 30 conducts current in the Y direction, i.e., perpendicularly to the longitudinal direction L or to the welding direction W, in the bonding region or in the welding zone locally delimited in the longitudinal direction L (X direction) by contact with the electrodes 31, 32, while the remaining regions of the heating element 30 are not supplied with current.

[0105] During the welding procedure, the electrodes 31, 32 are moved in the longitudinal direction L of the bond or of the heating element 30, i.e., in the welding direction W, and at the same time are in continuous electrical contact with the heating element 30 or with its respective contacted partial regions or electrically conductive elements 30a. In this manner, the locally delimited welding zone is moved in the heating element 30 in the welding direction W or in the direction of the welding movement (X direction), which corresponds to the longitudinal direction L of the planar heating element 30 or the weld seam. In this case, the heating element 30 remains fixed in place between the two skin sections 11, 12. (Step 2)

[0106] The contact pressure rollers 41, 42, which press the two skin sections 11, 12 against one another during the welding, are moved synchronously with the moved electrodes 31, 32.

[0107] After the welding together, the heating element 30 remains in the weld seam.

[0108] As the method is carried out, the respective parameters required for the welding procedure are taken into consideration. For example, the welding speed is preferably 100 to 350 mm/minute. A ceramic insulator is preferably used as the contact pressure element 41, 42, whereby the heat loss is reduced. The pressure force can be in the range of approximately 6 bar, for example. The bond has a shear strength which can be, for example, in the range of approximately 58 N/mm.sup.2 The skin thicknesses of the components to be welded or fuselage segments are in the range of 2 to 3 mm in many cases. However, they can also be substantially greater and can be, for example, 6 mm or more for example in the vicinity of door cutouts of a fuselage segment.

[0109] A side view of a rear fuselage section 80 of a commercial aircraft having longitudinal seams 81 welded according to the invention is shown in FIG. 6.

[0110] A cross section of the fuselage section 80 shown in FIG. 6 having the positions of the longitudinal seams 81 welded according to the invention is shown in FIG. 7.

[0111] FIG. 8 shows a longitudinal seam 81 welded according to the invention of a commercial aircraft having overlapping skin sections 11, 12 as a sectional view. A first skin section 11 arranged on top of a fuselage segment overlaps a region of a second skin section 12 arranged on the bottom. The heating element 30 is located between the two skin sections.

[0112] After the welding together, the heating element 30 can remain in the seam 81. It is particularly advantageous, in this case, if the heating element 30 has fibers and, in particular, carbon fibers as electrically conductive elements 30a. The fibers are arranged for the welding so that they are aligned in the load direction in the direction of the main load of the welded bond to be produced. The heating element 30 or its fibers is thus used after the welding procedure as a reinforcing element of the welded components 11, 12.

[0113] The heating element, the device, and the method as described above represent particularly preferred embodiments of the invention. In specific applications, for example, it is also possible to design only one contact pressure element as movable or as a roller, while the other, opposing contact pressure element is stationary and forms, for example, a stationary contact pressure surface below the overlap region of the two components 11, 12.

[0114] Furthermore, in specific cases, for example, only one electrode can be designed as movable or as a roller, while the other electrode is stationary and contacts a region of the heating element 30 in a planar manner. The movable electrodes can also be formed, for example, as a slip contact.

[0115] The invention results in enhanced strength in the region of the welded bond in relation to conventional bonds by way of thermoplastic welding, in which only the thermoplastic matrix is used for bonding the components. In particular, in this way very long components, in particular fuselage segments of aircraft or commercial aircraft, can be bonded to one another by means of resistance welding

[0116] Due to the invention, continuous heating with the aid of one or more movable elements takes place during the resistance welding, instead of heating the entire length of the welded bond to be produced at once. The power consumption and the current consumption during the resistance welding are thus reduced.

[0117] Since a continuously progressing heating only takes place locally at the location of the presently heated welding zone, power losses are minimized. In particular, very long components, in particular fuselage segments, can be bonded to one another by means of resistance welding. Tolerances for long components to be welded can be handled better. The welding process can be better controlled because of the continuous resistance welding.

[0118] In addition, the time expenditure during the production of fuselages of aircraft, in particular, is reduced by the method according to the invention, in particular using the multifunctional heating element.

[0119] While at least one exemplary embodiment of the present invention(s) is disclosed herein, it should be understood that modifications, substitutions and alternatives may be apparent to one of ordinary skill in the art and can be made without departing from the scope of this disclosure. This disclosure is intended to cover any adaptations or variations of the exemplary embodiment(s). In addition, in this disclosure, the terms comprise or comprising do not exclude other elements or steps, the terms a or one do not exclude a plural number, and the term or means either or both. Furthermore, characteristics or steps which have been described may also be used in combination with other characteristics or steps and in any order unless the disclosure or context suggests otherwise. This disclosure hereby incorporates by reference the complete disclosure of any patent or application from which it claims benefit or priority.

LIST OF REFERENCE SIGNS

[0120] 11 first component/first skin section [0121] 12 second component/second skin section [0122] 30 heating element [0123] 30a electrically conductive elements or fibers [0124] 31, 32 contact element/electrode [0125] 31a, 32a axes of rotation [0126] 34 insulators [0127] 35, 36 contact regions [0128] 37, 38 terminal elements [0129] 41, 42 contact pressure element or contact pressure roller [0130] 41a, 42a axes of rotation [0131] 50 voltage source [0132] 80 fuselage section [0133] 81 longitudinal seam [0134] L longitudinal direction [0135] M main load or main load direction [0136] W welding direction [0137] X longitudinal direction [0138] Y transverse or peripheral direction [0139] 110, 120 components [0140] 130 heating element [0141] 131, 132 connection clamps [0142] 133 voltage source