U.S. patent application number 16/736428 was filed with the patent office on 2021-07-08 for methods and apparatus for semi-automated tack welding of plies of a thermoplastic composite layup.
The applicant listed for this patent is The Boeing Company. Invention is credited to Daniel D. Bloch, Roger A. Burgess, Samuel J. Easley, Eric E. Moyes, Randall D. Wilkerson.
Application Number | 20210205936 16/736428 |
Document ID | / |
Family ID | 1000005666480 |
Filed Date | 2021-07-08 |
United States Patent
Application |
20210205936 |
Kind Code |
A1 |
Bloch; Daniel D. ; et
al. |
July 8, 2021 |
METHODS AND APPARATUS FOR SEMI-AUTOMATED TACK WELDING OF PLIES OF A
THERMOPLASTIC COMPOSITE LAYUP
Abstract
Methods and apparatus for semi-automated tack welding of plies
of a thermoplastic composite layup are described. An example
welding tool includes a stabilization foot, a housing, a compaction
foot, and a welder. The stabilization foot has a stabilization
surface. The housing has a central axis. The housing is movable
relative to the stabilization surface along the central axis of the
housing. The compaction foot has a central axis and a compaction
surface. The compaction surface is movable relative to the
stabilization surface and to the housing along the central axis of
the compaction surface. The welder has a central axis and a welding
surface. The welding surface is movable relative to the
stabilization surface, to the housing, and to the compaction
surface along the central axis of the welder.
Inventors: |
Bloch; Daniel D.; (St.
Peters, MO) ; Burgess; Roger A.; (Clayton, MO)
; Easley; Samuel J.; (St. Peters, MO) ; Moyes;
Eric E.; (Desoto, MO) ; Wilkerson; Randall D.;
(O'Fallon, MO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The Boeing Company |
Chicago |
IL |
US |
|
|
Family ID: |
1000005666480 |
Appl. No.: |
16/736428 |
Filed: |
January 7, 2020 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B23K 2103/16 20180801;
B23K 37/0408 20130101 |
International
Class: |
B23K 37/04 20060101
B23K037/04 |
Claims
1. A welding tool, comprising: a stabilization foot having a
stabilization surface; a housing having a central axis, the housing
being movable relative to the stabilization surface along the
central axis of the housing; a compaction foot having a central
axis and a compaction surface, the compaction surface being movable
relative to the stabilization surface and to the housing along the
central axis of the compaction foot; and a welder having a central
axis and a welding surface, the welding surface being movable
relative to the stabilization surface, to the housing, and to the
compaction surface along the central axis of the welder.
2. The welding tool of claim 1, wherein the central axis of the
housing, the central axis of the compaction foot, and the central
axis of the welder are parallel.
3. The welding tool of claim 1, wherein the central axis of the
housing, the central axis of the compaction foot, and the central
axis of the welder are coaxially aligned.
4. The welding tool of claim 1, wherein the compaction surface
circumscribes the welding surface, and wherein the stabilization
surface circumscribes the compaction surface.
5. The welding tool of claim 1, wherein the housing is movable
along the central axis of the housing between a neutral position
and a compressed position, and wherein the stabilization surface is
configured to stabilize a first thermoplastic part relative to a
second thermoplastic part when the housing is in the compressed
position.
6. The welding tool of claim 5, further comprising a spring
operatively positioned between the housing and the stabilization
foot, wherein the spring is configured to bias the housing into the
neutral position, and wherein the housing is configured to be
manually moved from the neutral position into the compressed
position against a spring force generated by the spring.
7. The welding tool of claim 1, wherein the compaction surface is
movable along the central axis of the compaction foot between a
retracted position and an extended position, and wherein the
compaction surface is configured to compact a first thermoplastic
part relative to a second thermoplastic part when the compaction
foot is in the extended position.
8. The welding tool of claim 7, wherein the compaction surface is
configured to be automatically moved from the retracted position to
the extended position in response to pressurized air delivered in a
controlled manner to a portion of the compaction foot located
within the housing.
9. The welding tool of claim 7, wherein the compaction surface is
positioned above the stabilization surface when the compaction
surface is in the retracted position, and wherein the compaction
surface is positioned flush with or below the stabilization surface
when the compaction surface is in the extended position.
10. The welding tool of claim 1, wherein the compaction surface is
movable along the central axis of the compaction foot between a
neutral position and a compressed position, and wherein the
compaction surface is configured to compact a first thermoplastic
part relative to a second thermoplastic part when the compaction
foot is in the compressed position.
11. The welding tool of claim 10, further comprising a spring
operatively positioned between the compaction foot and the housing,
wherein the spring is configured to bias the compaction foot into
the neutral position, and wherein the compaction foot is configured
to be manually moved from the neutral position into the compressed
position against a spring force generated by the spring.
12. The welding tool of claim 10, wherein the compaction surface is
positioned flush with or below the stabilization surface when the
compaction surface is in the compressed position.
13. The welding tool of claim 1, wherein the welding surface is
movable along the central axis of the welder between a retracted
position and an extended position, and wherein the welding surface
is configured to weld a first thermoplastic part to a second
thermoplastic part when the welding surface is in the extended
position.
14. The welding tool of claim 13, wherein the welding surface is
configured to be automatically moved from the retracted position to
the extended position in response to pressurized air delivered in a
controlled manner to an air cylinder located within the housing,
wherein the air cylinder is movable along the central axis of the
welder, and wherein the welder is fixedly coupled to the air
cylinder.
15. The welding tool of claim 13, wherein the welding surface is
positioned above the stabilization surface when the welding surface
is in the retracted position, and wherein the welding surface is
positioned flush with or below the stabilization surface when the
welding surface is in the extended position.
16. A method for welding a first thermoplastic part to a second
thermoplastic part via a welding tool, the method comprising:
positioning a stabilization surface of a stabilization foot of the
welding tool in contact with the first thermoplastic part;
stabilizing the first thermoplastic part relative to the second
thermoplastic part by moving a housing of the welding tool toward
the stabilization surface along a central axis of the housing;
compacting the first thermoplastic part relative to the second
thermoplastic part by moving a compaction surface of a compaction
foot of the welding tool into contact with the first thermoplastic
part and relative to the stabilization foot and to the housing
along a central axis of the compaction foot; and welding the first
thermoplastic part to the second thermoplastic part by moving a
welding surface of a welder of the welding tool into contact with
the first thermoplastic part and relative to the stabilization
surface, to the housing, and to the compaction surface along a
central axis of the welder.
17. The method of claim 16, wherein the central axis of the
housing, the central axis of the compaction foot, and the central
axis of the welder are parallel.
18. The method of claim 16, wherein the central axis of the
housing, the central axis of the compaction foot, and the central
axis of the welder are coaxially aligned.
19. The method of claim 16, wherein stabilizing the first
thermoplastic part relative to the second thermoplastic part
includes moving the housing along the central axis of the housing
from a neutral position to a compressed position.
20. The method of claim 19, wherein moving the housing from the
neutral position to the compressed position includes manually
moving the housing from the neutral position into the compressed
position against a spring force generated by a spring of the
welding tool, wherein the spring is operatively positioned between
the housing and the stabilization foot, and wherein the spring
biases the housing into the neutral position.
21. The method of claim 16, wherein compacting the first
thermoplastic part relative to the second thermoplastic part
includes moving the compaction surface along the central axis of
the compaction foot from a retracted position to an extended
position.
22. The method of claim 21, wherein moving the compaction surface
from the retracted position to the extended position includes
automatically moving the compaction surface from the retracted
position into the extended position by delivering pressurized air
in a controlled manner to a portion of the compaction foot located
within the housing.
23. The method of claim 21, wherein the compaction surface is
positioned above the stabilization surface when the compaction
surface is in the retracted position, and wherein the compaction
surface is positioned flush with or below the stabilization surface
when the compaction surface is in the extended position.
24. The method of claim 16, wherein compacting the first
thermoplastic part relative to the second thermoplastic part
includes moving the compaction surface along the central axis of
the compaction foot from a neutral position to a compressed
position.
25. The method of claim 24, wherein moving the compaction surface
from the neutral position to the compressed position includes
manually moving the compaction surface from the neutral position
into the compressed position against a spring force generated by a
spring of the welding tool, wherein the spring is operatively
positioned between the compaction foot and the housing, and wherein
the spring biases the compaction foot into the neutral
position.
26. The method of claim 24, wherein the compaction surface is
positioned flush with or below the stabilization surface when the
compaction surface is in the compressed position.
27. The method of claim 16, wherein welding the first thermoplastic
part to the second thermoplastic part includes moving the welding
surface along the central axis of the welder from a retracted
position to an extended position.
28. The method of claim 27, wherein moving the welding surface from
the retracted position to the extended position includes
automatically moving the welding surface from the retracted
position into the extended position by delivering pressurized air
in a controlled manner to an air cylinder located within the
housing, wherein the air cylinder is movable along the central axis
of the welder, and wherein the welder is fixedly coupled to the air
cylinder.
29. The method of claim 27, wherein the welding surface is
positioned above the stabilization surface when the welding surface
is in the retracted position, and wherein the welding surface is
positioned flush with or below the stabilization surface when the
welding surface is in the extended position.
Description
FIELD OF THE DISCLOSURE
[0001] This disclosure relates generally to methods and apparatus
for tack welding and, more specifically, to methods and apparatus
for semi-automated tack welding of plies of a thermoplastic
composite layup.
BACKGROUND
[0002] Conventional methods of assembling thermoplastic composite
layups require a substantial degree of manual labor and/or human
involvement in conjunction with performing various operations,
steps and/or stages of the assembly process. For example, such
conventional methods commonly require that individual thermoplastic
plies be tack welded to one another using a manually-operated
welding device (e.g., an ultrasonic welder or a hot iron welder) in
connection with forming the thermoplastic composite layup. Human
involvement in the tack welding operation of such conventional
methods limits the accuracy, efficiency, and repeatability of the
assembly process and, in some instances, exposes the human operator
of the manually-operated welding device to safety risks arising
from the welding tip of the manually-operated welding device being
unshrouded during the tack welding operation.
SUMMARY
[0003] Methods and apparatus for semi-automated tack welding of
plies of a thermoplastic layup are disclosed. In some examples, a
welding tool is disclosed. In some disclosed examples, the welding
tool includes a stabilization foot, a housing, a compaction foot,
and a welder. In some disclosed examples, the stabilization foot
has a stabilization surface. In some disclosed examples, the
housing has a central axis. In some disclosed examples, the housing
is movable relative to the stabilization surface along the central
axis of the housing. In some disclosed examples, the compaction
foot has a central axis and a compaction surface. In some disclosed
examples, the compaction surface is movable relative to the
stabilization surface and to the housing along the central axis of
the compaction foot. In some disclosed examples, the welder has a
central axis and a welding surface. In some disclosed examples, the
welding surface is movable relative to the stabilization surface,
to the housing, and to the compaction surface along the central
axis of the welder.
[0004] In some examples, a method for welding a first thermoplastic
part to a second thermoplastic part via a welding tool is
disclosed. In some disclosed examples, the method includes
positioning a stabilization surface of a stabilization foot of the
welding tool in contact with the first thermoplastic part. In some
disclosed examples, the method includes stabilizing the first
thermoplastic part relative to the second thermoplastic part by
moving a housing of the welding tool toward the stabilization
surface along a central axis of the housing. In some disclosed
examples, the method includes compacting the first thermoplastic
part relative to the second thermoplastic part by moving a
compaction surface of a compaction foot of the welding tool into
contact with the first thermoplastic part and relative to the
stabilization foot and to the housing along a central axis of the
compaction foot. In some disclosed examples, the method includes
welding the first thermoplastic part to the second thermoplastic
part by moving a welding surface of a welder of the welding into
contact with the first thermoplastic part and relative to the
stabilization surface, to the housing, and to the compaction
surface along a central axis of the welder.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a perspective view of an example welding tool
constructed in accordance with the teachings of this disclosure and
shown in a first example configuration.
[0006] FIG. 2 is a side view of the welding tool of FIG. 1 shown in
the first configuration of FIG. 1.
[0007] FIG. 3 is a bottom view of the welding tool of FIGS. 1 and 2
shown in the first configuration of FIGS. 1 and 2.
[0008] FIG. 4 is a partial cutaway view of the welding tool of
FIGS. 1-3 shown in the first configuration of FIGS. 1-3.
[0009] FIG. 5 is a cross-sectional view of the welding tool of
FIGS. 1-4 shown in the first configuration of FIGS. 1-4.
[0010] FIG. 6 is a cross-sectional view of the welding tool of
FIGS. 1-5 shown in a second example configuration.
[0011] FIG. 7 is a cross-sectional view of the welding tool of
FIGS. 1-6 shown in a third example configuration.
[0012] FIG. 8 is a cross-sectional view of the welding tool of
FIGS. 1-7 shown in a fourth example configuration.
[0013] FIG. 9 illustrates a first example stage of an example
process to be implemented via the welding tool of FIGS. 1-8 to weld
a first example thermoplastic part to a second example
thermoplastic part.
[0014] FIG. 10 illustrates a second example stage of the process of
FIG. 9.
[0015] FIG. 11 illustrates a third example stage of the process of
FIGS. 9 and 10.
[0016] FIG. 12 illustrates a fourth example stage of the process of
FIGS. 9-11.
[0017] FIG. 13 illustrates a fifth example stage of the process of
FIGS. 9-12.
[0018] FIG. 14 illustrates a sixth example stage of the process of
FIGS. 9-13.
[0019] FIG. 15 illustrates a seventh example stage of the process
of FIGS. 9-14.
[0020] FIG. 16 is a flowchart representative of an example method
for implementing the example welding tool of FIGS. 1-8 to weld a
first example thermoplastic part to a second example thermoplastic
part.
[0021] FIG. 17 is a perspective view of another example welding
tool constructed in accordance with the teachings of this
disclosure and shown in a first example configuration.
[0022] FIG. 18 is a side view of the welding tool of FIG. 17 shown
in the first configuration of FIG. 17.
[0023] FIG. 19 is a bottom view of the welding tool of FIGS. 17 and
18 shown in the first configuration of FIGS. 17 and 18.
[0024] FIG. 20 is a partial cutaway view of the welding tool of
FIGS. 17-19 shown in the first configuration of FIGS. 17-19.
[0025] FIG. 21 is a cross-sectional view of the welding tool of
FIGS. 17-20 shown in the first configuration of FIGS. 17-20.
[0026] FIG. 22 is a cross-sectional view of the welding tool of
FIGS. 17-21 shown in a second example configuration.
[0027] FIG. 23 is a cross-sectional view of the welding tool of
FIGS. 17-22 shown in a third example configuration.
[0028] FIG. 24 is a cross-sectional view of the welding tool of
FIGS. 17-23 shown in a fourth example configuration.
[0029] FIG. 25 illustrates a first example stage of an example
process to be implemented via the welding tool of FIGS. 17-25 to
weld a first example thermoplastic part to a second example
thermoplastic part.
[0030] FIG. 26 illustrates a second example stage of the process of
FIG. 25.
[0031] FIG. 27 illustrates a third example stage of the process of
FIGS. 25 and 26.
[0032] FIG. 28 illustrates a fourth example stage of the process of
FIGS. 25-27.
[0033] FIG. 29 illustrates a fifth example stage of the process of
FIGS. 25-28.
[0034] FIG. 30 illustrates a sixth example stage of the process of
FIGS. 25-29.
[0035] FIG. 31 illustrates a seventh example stage of the process
of FIGS. 25-30.
[0036] FIG. 32 is a flowchart representative of an example method
for implementing the example welding tool of FIGS. 17-25 to weld a
first example thermoplastic part to a second example thermoplastic
part.
[0037] Certain examples are shown in the above-identified figures
and described in detail below. In describing these examples, like
or identical reference numbers are used to identify the same or
similar elements. The figures are not necessarily to scale and
certain features and certain views of the figures may be shown
exaggerated in scale or in schematic for clarity and/or
conciseness.
DETAILED DESCRIPTION
[0038] As discussed above, conventional methods of assembling
thermoplastic composite layups commonly require that individual
thermoplastic plies be tack welded to one another using a
manually-operated welding device (e.g., an ultrasonic welder or a
hot iron welder) in connection with forming the thermoplastic
composite layup. The human operator of the manually-operated
welding device typically places a first thermoplastic ply into
position on top of (e.g., stacked relative to) a second
thermoplastic ply of a composite thermoplastic layup, and then tack
welds the first thermoplastic ply to the second thermoplastic ply
and/or to the thermoplastic composite layup. To perform the tack
welding operation, the human operator pushes the manually-operated
welding device against the first thermoplastic ply with a
subjective pressure, for a subjective time, until the human
operator concludes that the tack weld is successful.
[0039] During the tack welding operation, the welding tip of the
manually-operated welding device must be used to debulk the
thermoplastic plies (e.g., the first thermoplastic ply and the
second thermoplastic ply) of the thermoplastic composite layup.
Such debulking becomes increasingly more difficult for the human
operator to manage and/or control as the number of plies and/or the
associated bulk (e.g., the squishiness or yield of the stacked
plies to the touch) of the thermoplastic composite layup increases,
and/or as the thermoplastic composite layup develops one or more
significant taper(s) resulting from the formation of one or more
ply drop(s) (e.g., progressively smaller thermoplastic plies
stacked on each other) within the thermoplastic composite layup. As
the number of plies and/or the associated bulk of the thermoplastic
composite layup increases, so too does the tendency of the
thermoplastic composite layup to push back (e.g., via a counter
pressure) against the tack weld when the human operator releases
the welding tip of the manually-operated welding device. In some
instances, such push-back is substantial enough to cause the tack
weld to fracture, break, and/or otherwise fail. The tack weld can
also fracture, break, and/or otherwise fail when the human operator
releases the welding tip of the manually-operated welding device
while the tack welded area of the thermoplastic composite layup is
still hot (e.g., before the thermoplastic plies being welded
together have cooled to a temperature below their melting points).
Additionally, the tack welding operation may expose the human
operator of the manually-operated welding device to safety risks
arising from the welding tip of the manually-operated welding
device being unshrouded during the tack welding operation.
[0040] Example methods and apparatus for semi-automated tack
welding of plies of a thermoplastic composite layup are disclosed
herein. The disclosed methods and apparatus include and/or utilize
a welding tool having a stabilization foot configured to stabilize
a first thermoplastic ply relative to a second thermoplastic ply, a
compaction foot configured to compact and/or debulk the first
thermoplastic ply relative to the second thermoplastic ply, and a
welder configured to tack weld the first thermoplastic ply to the
second thermoplastic ply in connection with forming a thermoplastic
composite layup. In some disclosed examples, the stabilization foot
of the welding tool configured to stabilize the first thermoplastic
ply relative to the second thermoplastic ply in response to a
housing of the welding tool being manually moved (e.g., by a human
operator of the welding tool) toward the stabilization foot. In
some disclosed examples, the stabilization foot of the welding tool
is configured to be manually operated and/or manually controlled by
a human operator of the welding tool, and the compaction foot and
the welder of the welding tool are configured to be automatically
operated and/or automatically controlled. In other disclosed
examples, the stabilization foot and the compaction foot of the
welding tool are configured to be manually operated and/or manually
controlled by a human operator of the welding tool, and the welder
of the welding tool is configured to be automatically operated
and/or automatically controlled.
[0041] The disclosed methods and apparatus provide numerous
advantages relative to conventional manual tack welding operations.
For example, the disclosed methods and apparatus advantageously
enable a human operator to stabilize and debulk one or more
thermoplastic plies of a thermoplastic composite layup in a
controlled manner as the plies are tack welded, and/or to apply the
correct amount of weld pressure, for the correct time period, to
facilitate tack welding the plies of the thermoplastic composite
layup. The disclosed method and apparatus accordingly reduce and/or
eliminate much or all of the subjectivity that is inherent in
conventional manual tack welding operations. Additionally, the
disclosed methods and apparatus advantageously cause the welding
tip of the welder of the welding tool to be shrouded (e.g., by the
compaction foot of the welding tool and/or by the stabilization
foot of the welding tool) while the tack weld is formed. The
disclosed method and apparatus may accordingly provide a safety
advantage to a human operator of the welding tool relative to the
safety risks that the human operator may be inherently exposed to
in connection with conventional manual tack welding operations.
[0042] As used herein, the term "thermoplastic part" refers to a
thermoplastic material (e.g., one or more plies, sheets, or layers
of thermoplastic material) to be incorporated into a thermoplastic
composite layup. A thermoplastic part can be, for example, one or
more plies of fiber pre-impregnated with thermoplastic resin (e.g.,
prepreg). The fiber can be formed, for example, from carbon,
fiberglass, or Kevlar. The fiber can be unidirectional, or can
alternatively be a multidirectional weave or fabric. As used
herein, the term "thermoplastic composite layup" refers generally
to any thermoplastic article including at least two thermoplastic
parts that have been welded (e.g., tack welded) to one another to
form the thermoplastic article. Further processing, for example
through the application of heat and pressure, of a thermoplastic
composite layup creates a thermoplastic composite structure. The
end use of the thermoplastic composite structure determines the
specific configuration (e.g., number of plies, size and shape of
plies, or relative orientation of adjacent plies) of the
thermoplastic parts in the thermoplastic composite layup.
[0043] As used herein in the context of a first object
circumscribing a second object, the term "circumscribe" means that
the first object is constructed around and/or defines an area
around the second object. In interpreting the term "circumscribe"
as used herein, it is to be understood that the first object
circumscribing the second object can include gaps and/or can
consist of multiple spaced-apart objects, such that a boundary
formed by the first object around the second object is not
necessarily a continuous boundary. For example, a plurality of
trees can circumscribe a field.
[0044] As used herein in the context of describing various
positions of the housing, the stabilization foot, the compaction
foot, and/or the welder of any of the example welding tools
disclosed herein, the terms "uncompressed position," "compressed
position," "retracted position," and "extended position" are
relative in nature. For example, describing the housing as being in
an uncompressed position relative to a surface and/or relative to
another structure does not necessarily mean that the housing is in
a fully-uncompressed position. Similarly, describing the housing as
being in a compressed position relative to a surface and/or
relative to another structure does not necessarily mean that the
housing is in a fully-compressed position. In this same light,
describing the compaction foot as being in an uncompressed position
relative to a surface and/or relative to another structure does not
necessarily mean that the compaction foot is in a
fully-uncompressed position. And similarly, describing the
compaction foot as being in a compressed position relative to a
surface and/or relative to another structure does not necessarily
mean that the compaction foot is in a fully-compressed position. In
this same light, describing the compaction foot as being in a
retracted position relative to a surface and/or relative to another
structure does not necessarily mean that the compaction foot is in
a fully-retracted position. And similarly, describing the
compaction foot as being in an extended position relative to a
surface and/or relative to another structure does not necessarily
mean that the compaction foot is in a fully-extended position. In
this same light, describing the welder as being in a retracted
position relative to a surface and/or relative to another structure
does not necessarily mean that the welder is in a fully-retracted
position. And similarly, describing the welder as being in an
extended position relative to a surface and/or relative to another
structure does not necessarily mean that the welder is in a
fully-extended position.
[0045] FIG. 1 is a perspective view of an example welding tool 100
constructed in accordance with the teachings of this disclosure and
shown in a first example configuration 102. FIG. 2 is a side view
of the welding tool 100 shown in the first configuration 102. FIG.
3 is a bottom view of the welding tool 100 shown in the first
configuration 102. FIG. 4 is a partial cutaway view of the welding
tool 100 shown in the first configuration 102. FIG. 5 is a
cross-sectional view of the welding tool 100 shown in the first
configuration 102. FIG. 6 is a cross-sectional view of the welding
tool 100 shown in a second example configuration 602. FIG. 7 is a
cross-sectional view of the welding tool 100 shown in a third
example configuration 702. FIG. 8 is a cross-sectional view of the
welding tool 100 shown in a fourth example configuration 802.
[0046] The welding tool 100 of FIGS. 1-8 includes an example
housing 104, an example stabilization foot 106, a first example rod
108, a second example rod 110, a first example spring 112, a second
example spring 114, a first example hand grip 116, a second example
hand grip 118, an example cap 120, a first example air pressure
conduit 122, a second example air pressure conduit 124, a third
example air pressure conduit 126, a fourth example air pressure
conduit 128, an example ultrasonic exciter 130, an example
compaction foot 302, an example welder 304, and an example air
cylinder 402.
[0047] The housing 104 of the welding tool 100 is configured to
house, receive, contain, and/or carry one or more portion(s) of the
first rod 108, the second rod 110, the first hand grip 116, the
second hand grip 118, the cap 120, the first air pressure conduit
122, the second air pressure conduit 124, the third air pressure
conduit 126, the fourth air pressure conduit 128, the ultrasonic
exciter 130, the compaction foot 302, the welder 304, and/or the
air cylinder 402 of the welding tool 100. In the illustrated
example of FIGS. 1-8, the housing 104 includes an example central
portion 132. The central portion 132 of the housing 104 includes an
example upper (e.g., top) end 134, an example lower (e.g., bottom)
end 136 located opposite the upper end 134, an example sidewall 138
extending between the upper end 134 and the lower end 136, and an
example central axis 140. The upper end 134 of the central portion
132 is oriented away from the stabilization foot 106, and the lower
end 136 of the central portion 132 is oriented toward the
stabilization foot 106. In the illustrated example of FIGS. 1-8,
the sidewall 138 of the central portion 132 has a circular
cross-sectional shape and/or area. In other examples, the sidewall
138 of the central portion 132 can have a different cross-sectional
shape and/or area (e.g., a non-circular cross-sectional shape
and/or area, a differently sized cross-sectional shape and/or area,
etc.).
[0048] Referring to FIG. 4, which is a cutaway view showing
interior structure of the welding tool 100, the central portion 132
of the housing 104 can be seen to include an example opening 404
defined by the sidewall 138. The opening 404 of the central portion
132 extends from the upper end 134 of the central portion 132
through to the lower end 136 of the central portion 132 in a
direction parallel to and coaxially aligned with the central axis
140. The opening 404 of the central portion 132 is configured to
receive one or more portion(s) of the cap 120, the ultrasonic
exciter 130, the compaction foot 302, the welder 304, and/or the
air cylinder 402 of the welding tool 100, such that the received
portion(s) of the cap 120, the ultrasonic exciter 130, the
compaction foot 302, the welder 304, and/or the air cylinder 402
is/are circumscribed and/or otherwise bounded by the sidewall 138
of the central portion 132 of the housing 104, as further described
below. In the illustrated example of FIGS. 1-8, the opening 404 of
the central portion 132 has a circular cross-sectional shape and/or
area. In other examples, the opening 404 of the central portion 132
can have a different cross-sectional shape and/or area (e.g., a
non-circular cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0049] As can be seen in FIG. 4, the central portion 132 of the
housing 104 further includes a first example inwardly-extending
flange 406 located between the upper end 134 and the lower end 136
of the central portion 132 and extending inwardly from the sidewall
138, and a second example inwardly-extending flange 408 located at
and/or proximate to the lower end 136 of the central portion 132
and extending inwardly from the sidewall 138. The first
inwardly-extending flange 406 of the central portion 132 separates
the opening 404 of the central portion 132 into a first example
cavity 410 and a second example cavity 412. The first cavity 410 of
the opening 404 is bounded by the sidewall 138 of the central
portion 132, and extends between the upper end 134 of the central
portion 132 and the first inwardly-extending flange 406 of the
central portion 132. The second cavity 412 is bounded by the
sidewall 138 of the central portion 132, and extends between the
first inwardly-extending flange 406 of the central portion 132 and
the second inwardly-extending flange 408 of the central portion
132. In the illustrated example of FIGS. 1-8, the first and second
inwardly-extending flanges 406, 408 of the central portion 132 and
the first and second cavities 410, 412 of the opening 404 each have
a circular cross-sectional shape and/or area. In other examples,
one or more of the first and second inwardly-extending flanges 406,
408 of the central portion 132 and/or the first and second cavities
410, 412 of the opening 404 can have a different cross-sectional
shape and/or area (e.g., a non-circular cross-sectional shape
and/or area, a differently sized cross-sectional shape and/or area,
etc.).
[0050] In addition to the central portion 132 described above, the
housing 104 further includes a first example arm 142 coupled to and
extending laterally (e.g., radially) away from the central portion
132 in a first direction, and a second example arm 144 coupled to
and extending laterally (e.g., radially) away from the central
portion 132 in a second direction that is generally opposite the
first direction. Thus, the first arm 142 and the second arm 144 are
generally located on opposite sides of the central portion 132 of
the housing 104. In the illustrated example of FIGS. 1-8, the first
arm 142 and the second arm 144 are integrally formed with the
central portion 132 of the housing 104. In other examples, the
first arm 142 and/or the second arm 144 can alternatively be
coupled (e.g., rigidly and/or fixedly coupled) to the central
portion 132 of the housing 104 via one or more mechanical
fastener(s).
[0051] The first arm 142 of the housing 104 includes an example
upper (e.g., top) end 146, an example lower (e.g., bottom) end 148
located opposite the upper end 146, and an example sidewall 150
extending between the upper end 146 and the lower end 148. The
upper end 146 of the first arm 142 is oriented away from the
stabilization foot 106, and the lower end 148 of the first arm 142
is oriented toward the stabilization foot 106. In the illustrated
example of FIGS. 1-8, the sidewall 150 of the first arm 142 has a
circular cross-sectional shape and/or area. In other examples, the
sidewall 150 of the first arm 142 can have a different
cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0052] Referring to FIG. 5, which shows a cross-sectional view of
the welding tool 100, the first arm 142 of the housing 104 can be
seen to include an example opening 502 defined by the sidewall 150.
The opening 502 of the first arm 142 extends from the upper end 146
of the first arm 142 through to the lower end 148 of the first arm
142 in a direction parallel to and laterally (e.g., radially)
offset from the central axis 140 of the central portion 132 of the
housing 104. The opening 502 of the first arm 142 is configured to
receive a portion of the first rod 108 of the welding tool 100 such
that the received portion of the first rod 108 is circumscribed
and/or otherwise bounded by the sidewall 150 of the first arm 142
of the housing 104. The opening 502 of the first arm 142 slidably
receives the first rod 108 of the welding tool 100 such that the
first arm 142 and/or, more generally, the housing 104 of the
welding tool 100 is slidable along the first rod 108 relative to
(e.g., toward and/or away from) the stabilization foot 106 of the
welding tool 100. In the illustrated example of FIGS. 1-8, the
opening 502 of the first arm 142 has a circular cross-sectional
shape and/or area. In other examples, the opening 502 of the first
arm 142 can have a different cross-sectional shape and/or area
(e.g., a non-circular cross-sectional shape and/or area, a
differently sized cross-sectional shape and/or area, etc.).
[0053] The second arm 144 of the housing 104 includes an example
upper (e.g., top) end 152, an example lower (e.g., bottom) end 154
located opposite the upper end 152, and an example sidewall 156
extending between the upper end 152 and the lower end 154. The
upper end 152 of the second arm 144 is oriented away from the
stabilization foot 106, and the lower end 154 of the second arm 144
is oriented toward the stabilization foot 106. In the illustrated
example of FIGS. 1-8, the sidewall 156 of the second arm 144 has a
circular cross-sectional shape and/or area. In other examples, the
sidewall 156 of the second arm 144 can have a different
cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0054] Referring to FIG. 5, the second arm 144 of the housing 104
can be seen to include an example opening 504 defined by the
sidewall 156. The opening 504 of the second arm 144 extends from
the upper end 152 of the second arm 144 through to the lower end
154 of the second arm 144 in a direction parallel to and laterally
(e.g. radially) offset from the central axis 140 of the central
portion 132 of the housing 104. The opening 504 of the second arm
144 is configured to receive a portion of the second rod 110 of the
welding tool 100 such that the received portion of the second rod
110 is circumscribed and/or otherwise bounded by the sidewall 156
of the second arm 144 of the housing 104. The opening 504 of the
second arm 144 slidably receives the second rod 110 of the welding
tool 100 such that the second arm 144 and/or, more generally, the
housing 104 of the welding tool 100 is slidable along the second
rod 110 relative to (e.g., toward and/or away from) the
stabilization foot 106 of the welding tool 100. In the illustrated
example of FIGS. 1-8, the opening 504 of the second arm 144 has a
circular cross-sectional shape and/or area. In other examples, the
opening 504 of the second arm 144 can have a different
cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0055] As discussed above, the first and second arms 142, 144 of
the housing 104 are integrally formed with the central portion 132
of the housing 104. The central portion 132, the first arm 142, and
the second arm 144 of the housing 104 are accordingly movable
(e.g., slidable) in unison relative to (e.g., toward and/or away
from) the stabilization foot 106. Movement of the housing 104
(e.g., including the central portion 132 and the first and second
arms 142, 144) toward the stabilization foot 106 is manually
performed and/or manually controlled by a user (e.g., a human
operator) of the welding tool 100, and is facilitated via the first
hand grip 116 and/or the second hand grip 118 of the welding tool
100. In the illustrated example of FIGS. 1-8, the first hand grip
116 is coupled to and extends away from the first arm 142 and/or
the central portion 132 of the housing 104 in a first direction,
and the second hand grip 118 is coupled to and extends away from
the second arm 144 and/or the central portion 132 of the housing
104 in a second direction that is generally opposite the first
direction. Thus, the first hand grip 116 and the second hand grip
118 are generally located on opposite sides of the central portion
132 of the housing 104. The first hand grip 116 and the second hand
grip 118 are ergonomically configured (e.g., ergonomically, sized,
shaped, oriented, and/or arranged) to be efficiently and/or
comfortably gripped, grasped, and/or held by the hands of an
average adult-sized user of the welding tool 100. In the
illustrated example of FIGS. 1-8, the first hand grip 116 and the
second hand grip 118 each have an ellipsoidal and/or bulb-like
shape. In other examples, the first hand grip 116 and/or the second
hand grip 118 can have a different shape (e.g., a non-ellipsoidal
and/or non-bulb-like shape).
[0056] The stabilization foot 106 of the welding tool 100 is
configured to engage and/or stabilize one or more thermoplastic
part(s) of a thermoplastic composite layup prior to, during, and/or
following a compaction operation to be performed using the welding
tool 100, and/or prior to, during, and/or following a welding
operation to be performed using the welding tool 100. In the
illustrated example of FIGS. 1-8, the stabilization foot 106
includes an example base 158. The base 158 of the stabilization
foot 106 includes an example upper surface 160, an example lower
(e.g., bottom) surface 162 located opposite the upper surface 160,
an example peripheral edge 164 extending between the upper surface
160 and the lower surface 162, and an example central axis 166. The
upper surface 160 of the base 158 is oriented toward the central
portion 132 of the housing 104, and the lower surface 162 of the
base 158 is oriented away from the central portion 132 of the
housing 104. Referring also to FIG. 3, which shows a bottom view of
welding tool 100, the lower surface 162 of the base 158 can be seen
to form an example stabilization surface 306 that is configured to
engage and/or stabilize one or more thermoplastic part(s) of a
thermoplastic composite layup. In the illustrated example of FIGS.
1-8, the stabilization surface 306 of the base 158 is substantially
flat and/or planar. In other examples, the stabilization surface
306 of the base 158 can alternatively be curved (e.g., non-planar),
contoured, or otherwise shaped to support and/or complement an
associated geometry of one or more thermoplastic part(s) of a
thermoplastic composite layup. The central axis 166 of the base 158
of the stabilization foot 106 is parallel to and coaxially aligned
with the central axis 140 of the central portion 132 of the housing
104. In the illustrated example of FIGS. 1-8, the peripheral edge
164 and the stabilization surface 306 of the base 158 each have a
circular cross-sectional shape and/or area. In other examples, the
peripheral edge 164 and/or the stabilization surface 306 of the
base 158 can have a different cross-sectional shape and/or area
(e.g., a non-circular cross-sectional shape and/or area, a
differently sized cross-sectional shape and/or area, etc.).
[0057] As can be seen in FIG. 3, the base 158 of the stabilization
foot 106 includes an example central opening 308, a first example
offset opening 310, and a second example offset opening 312. The
central opening 308 of the base 158 extends from the upper surface
160 of the base 158 through to the lower surface 162 of the base
158 in a direction parallel to and coaxially aligned with central
axis 166. In the illustrated example of FIGS. 1-8, the central
opening 308 of the base 158 of the stabilization foot 106 is
parallel to and coaxially aligned with the opening 404 of the
central portion 132 of the housing 104. The central opening 308 of
the base 158 is configured to receive (e.g., slidably receive) one
or more portion(s) of the compaction foot 302 and/or the welder 304
such that the received portion(s) of the compaction foot 302 and/or
the welder 304 is/are circumscribed and/or otherwise bounded by the
base 158 of the stabilization foot 106, as further described below.
In the illustrated example of FIGS. 1-8, the central opening 308 of
the base 158 has a circular cross-sectional shape and/or area. In
other examples, the central opening 308 of the base 158 can have a
different cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0058] The first offset opening 310 of the base 158 extends from
the upper surface 160 of the base 158 through to the lower surface
162 of the base 158 in a direction parallel to and laterally (e.g.,
radially) offset from the central axis 166. In the illustrated
example of FIGS. 1-8, the first offset opening 310 of the base 158
of the stabilization foot 106 is parallel to and coaxially aligned
with the opening 502 of the first arm 142 of the housing 104. The
first offset opening 310 of the base 158 is configured to receive a
portion of the first rod 108 of the welding tool 100 such that the
received portion of the first rod 108 is circumscribed and/or
otherwise bounded by the base 158 of the stabilization foot 106, as
further described below. In the illustrated example of FIGS. 1-8,
the first offset opening 310 of the base 158 has a circular
cross-sectional shape and/or area. In other examples, the first
offset opening 310 of the base 158 can have a different
cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0059] The second offset opening 312 of the base 158 extends from
the upper surface 160 of the base 158 through to the lower surface
162 of the base 158 in a direction parallel to and laterally (e.g.,
radially) offset from the central axis 166. In the illustrated
example of FIGS. 1-8, the second offset opening 312 of the base 158
of the stabilization foot 106 is parallel to and coaxially aligned
with the opening 504 of the second arm 144 of the housing 104. The
second offset opening 312 of the base 158 is configured to receive
a portion of the second rod 110 of the welding tool 100 such that
the received portion of the second rod 110 is circumscribed and/or
otherwise bounded by the base 158 of the stabilization foot 106, as
further described below. In the illustrated example of FIGS. 1-8,
the second offset opening 312 of the base 158 has a circular
cross-sectional shape and/or area. In other examples, the second
offset opening 312 of the base 158 can have a different
cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0060] While the base 158 of the stabilization foot 106 shown in
FIGS. 1-8 includes the central opening 308, the first offset
opening 310, and the second offset opening 312 as described above,
in other examples the first offset opening 310 and/or the second
offset opening 312 can be omitted from the base 158 of the
stabilization foot 106. For example, the base 158 of the
stabilization foot 106 can alternatively include the central
opening 308, and can omit the first and second offset openings 310,
312.
[0061] In addition to the base 158 described above, the
stabilization foot 106 further includes a first example leg 168 and
a second example leg 170 respectively coupled to and extending
upward from the base 158. The second leg 170 is located above the
first offset opening 310 of the base 158 of the stabilization foot
106, and the second leg 170 is located above the second offset
opening 312 of the base 158 of the stabilization foot 106. In the
illustrated example of FIGS. 1-8, the first leg 168 and the second
leg 170 are integrally formed with the base 158 of the
stabilization foot 106. In other examples, the first leg 168 and/or
the second leg 170 can alternatively be coupled (e.g., rigidly
and/or fixedly coupled) to the base 158 of the stabilization foot
106 via one or more mechanical fastener(s).
[0062] The first leg 168 of the stabilization foot 106 includes an
example upper (e.g., top) end 172, an example lower (e.g., bottom)
end 174 located opposite the upper end 172, and an example sidewall
176 extending between the upper end 172 and the lower end 174. The
upper end 172 of the first leg 168 is oriented toward the first arm
142 of the housing 104, and the lower end 174 of the first leg 168
is oriented away from the first arm 142 of the housing 104. In the
illustrated example of FIGS. 1-8, the sidewall 176 of the first leg
168 has a circular cross-sectional shape and/or area. In other
examples, the sidewall 176 of the first leg 168 can have a
different cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0063] Referring to FIG. 5, the first leg 168 of the stabilization
foot 106 can be seen to include an example opening 506 defined by
the sidewall 176. The opening 506 of the first leg 168 extends from
the upper end 172 of the first leg 168 through to the lower end 174
of the first leg 168 in a direction parallel to and laterally (e.g.
radially) offset from the central axis 166 of the base 158 of the
stabilization foot 106. In the illustrated example of FIGS. 1-8,
the opening 506 of the first leg 168 of the stabilization foot 106
is parallel to and coaxially aligned with the opening 502 of the
first arm 142 of the housing 104, and/or parallel to and coaxially
aligned with the first offset opening 310 of the base 158 of the
stabilization foot 106. The opening 506 of the first leg 168 is
configured to receive a portion of the first rod 108 of the welding
tool 100 such that the received portion of the first rod 108 is
circumscribed and/or otherwise bounded by the sidewall 176 of the
first leg 168 of the stabilization foot 106. The opening 506 of the
first leg 168 receives the first rod 108 such that the first rod
108 is rigidly, fixedly, and/or non-movably coupled (e.g., via a
threaded engagement, an adhesive, etc.) to the first leg 168
and/or, more generally, to the stabilization foot 106. In the
illustrated example of FIGS. 1-8, the opening 506 of the first leg
168 has a circular cross-sectional shape and/or area. In other
examples, the opening 506 of the first leg 168 can have a different
cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0064] The second leg 170 of the stabilization foot 106 includes an
example upper (e.g., top) end 178, an example lower (e.g., bottom)
end 180 located opposite the upper end 178, and an example sidewall
182 extending between the upper end 178 and the lower end 180. The
upper end 178 of the second leg 170 is oriented toward the second
arm 144 of the housing 104, and the lower end 180 of the second leg
170 is oriented away from the second arm 144 of the housing 104. In
the illustrated example of FIGS. 1-8, the sidewall 182 of the
second leg 170 has a circular cross-sectional shape and/or area. In
other examples, the sidewall 182 of the second leg 170 can have a
different cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0065] Referring to FIG. 5, the second leg 170 of the stabilization
foot 106 can be seen to include an example opening 508 defined by
the sidewall 182. The opening 508 of the second leg 170 extends
from the upper end 178 of the second leg 170 through to the lower
end 180 of the second leg 170 in a direction parallel to and
laterally (e.g. radially) offset from the central axis 166 of the
base 158 of the stabilization foot 106. In the illustrated example
of FIGS. 1-8, the opening 508 of the second leg 170 of the
stabilization foot 106 is parallel to and coaxially aligned with
the opening 504 of the second arm 144 of the housing 104, and/or
parallel to and coaxially aligned with the second offset opening
312 of the base 158 of the stabilization foot 106. The opening 508
of the second leg 170 is configured to receive a portion of the
second rod 110 of the welding tool 100 such that the received
portion of the second rod 110 is circumscribed and/or otherwise
bounded by the sidewall 182 of the second leg 170 of the
stabilization foot 106. The opening 508 of the second leg 170
receives the second rod 110 such that the second rod 110 is
rigidly, fixedly, and/or non-movably coupled (e.g., via a threaded
engagement, an adhesive, etc.) to the second leg 170 and/or, more
generally, to the stabilization foot 106. In the illustrated
example of FIGS. 1-8, the opening 508 of the second leg 170 has a
circular cross-sectional shape and/or area. In other examples, the
opening 508 of the second leg 170 can have a different
cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0066] The first rod 108 of the welding tool 100 is configured to
guide movement of the housing 104 of the welding tool 100 relative
to (e.g., toward or away from) the stabilization foot 106. In the
illustrated example of FIGS. 1-8, the first rod 108 includes an
example upper (e.g., top) end 184, and, as can be seen in FIG. 3,
an example lower (e.g., bottom) end 314 located opposite the upper
end 184. A portion of the first rod 108 proximate the upper end 184
of the first rod 108 is located and/or positioned within the
opening 502 of the first arm 142 of the housing 104 such that the
first arm 142 of the housing 104 is slidably coupled to the first
rod 108. In some examples, a portion of the first rod 108 located
proximate the upper end 184 of the first rod 108 can include a
mechanical stop (e.g., an outwardly-extending flange) configured to
prevent the first arm 142 of the housing 104 from sliding upwardly
past and/or off of the upper end 184 of the first rod 108. A
portion of the first rod 108 proximate the lower end 314 of the
first rod 108 is located and/or positioned within the opening 506
of the first leg 168 of the stabilization foot 106 and/or within
the first offset opening 310 of the base 158 of the stabilization
foot 106 such that the first rod 108 is rigidly and/or fixedly
coupled to the first leg 168 and/or the base 158 of the
stabilization foot 106. In some examples, a portion of the first
rod 108 proximate the lower end 314 of the first rod 108 can
include threads configured to mate with a threaded portion of the
opening 506 of the first leg 168 of the stabilization foot 106
and/or with a threaded portion of the first offset opening 310 of
the base 158 of the stabilization foot 106 to rigidly and/or
fixedly couple the first rod 108 to the first leg 168 and/or the
base 158 of the stabilization foot 106. In the illustrated example
of FIGS. 1-8, the first rod 108 has a circular cross-sectional
shape and/or area. In other examples, the first rod 108 can have a
different cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0067] The second rod 110 of the welding tool 100 is also
configured to guide movement of the housing 104 of the welding tool
100 relative to (e.g., toward or away from) the stabilization foot
106. In the illustrated example of FIGS. 1-8, the second rod 110
includes an example upper (e.g., top) end 186, and, as can be seen
in FIG. 3, an example lower (e.g., bottom) end 316 located opposite
the upper end 186. A portion of the second rod 110 proximate the
upper end 186 of the second rod 110 is located and/or positioned
within the opening 504 of the second arm 144 of the housing 104
such that the second arm 144 of the housing 104 is slidably coupled
to the second rod 110. In some examples, a portion of the second
rod 110 located proximate the upper end 186 of the second rod 110
can include a mechanical stop (e.g., an outwardly-extending flange)
configured to prevent the second arm 144 of the housing 104 from
sliding upwardly past and/or off of the upper end 186 of the second
rod 110. A portion of the second rod 110 proximate the lower end
316 of the second rod 110 is located and/or positioned within the
opening 508 of the second leg 170 of the stabilization foot 106
and/or within the second offset opening 312 of the base 158 of the
stabilization foot 106 such that the second rod 110 is rigidly
and/or fixedly coupled to the second leg 170 and/or the base 158 of
the stabilization foot 106. In some examples, a portion of the
second rod 110 proximate the lower end 316 of the second rod 110
can include threads configured to mate with a threaded portion of
the opening 508 of the second leg 170 of the stabilization foot 106
and/or with a threaded portion of the second offset opening 312 of
the base 158 of the stabilization foot 106 to rigidly and/or
fixedly couple the second rod 110 to the second leg 170 and/or the
base 158 of the stabilization foot 106. In the illustrated example
of FIGS. 1-8, the second rod 110 has a circular cross-sectional
shape and/or area. In other examples, the second rod 110 can have a
different cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0068] The first spring 112 of the welding tool 100 is configured
to bias the housing 104 of the welding tool 100 away from the
stabilization foot 106 of the welding tool 100. In the illustrated
example of FIGS. 1-8, the first spring 112 circumscribes (e.g., is
coiled about and/or around) the first rod 108, and is located
and/or positioned on the first rod 108 between the first arm 142 of
the housing 104 and the first leg 168 of the stabilization foot
106. The first spring 112 includes an example upper (e.g., top) end
188 in contact with the lower end 148 of the first arm 142 of the
housing 104, and an example lower (e.g., bottom) end 190 located
opposite the upper end 188 and in contact with the upper end 172 of
the first leg 168 of the stabilization foot 106. The first spring
112 biases the first arm 142 of the housing 104 away from the first
leg 168 of the stabilization foot 106 and/or, more generally,
biases the housing 104 of the welding tool 100 away from the
stabilization foot 106 of the welding tool 100. In the illustrated
example of FIGS. 1-8, the first spring 112 is compressible in
response to a downward force of sufficient magnitude (e.g., a
magnitude greater than that of a spring force associated with the
first spring 112) applied to the first arm 142 of the housing 104
(e.g., by a human operator of the welding tool 100 via the first
hand grip 116). Compression of the first spring 112 by such an
applied downward force enables the first arm 142 of the housing 104
to move and/or slide toward the first leg 168 of the stabilization
foot 106 and/or, more generally, enables the housing 104 to move
and/or slide toward the stabilization foot 106.
[0069] The second spring 114 of the welding tool 100 is also
configured to bias the housing 104 of the welding tool 100 away
from the stabilization foot 106 of the welding tool 100. In the
illustrated example of FIGS. 1-8, the second spring 114
circumscribes (e.g., is coiled about and/or around) the second rod
110, and is located and/or positioned on the second rod 110 between
the second arm 144 of the housing 104 and the second leg 170 of the
stabilization foot 106. The second spring 114 includes an example
upper (e.g., top) end 192 in contact with the lower end 154 of the
second arm 144 of the housing 104, and an example lower (e.g.,
bottom) end 194 located opposite the upper end 192 and in contact
with the upper end 178 of the second leg 170 of the stabilization
foot 106. The second spring 114 biases the second arm 144 of the
housing 104 away from the second leg 170 of the stabilization foot
106 and/or, more generally, biases the housing 104 of the welding
tool 100 away from the stabilization foot 106 of the welding tool
100. In the illustrated example of FIGS. 1-8, the second spring 114
is compressible in response to a downward force of sufficient
magnitude (e.g., a magnitude greater than that of a spring force
associated with the second spring 114) applied to the second arm
144 of the housing 104 (e.g., by a human operator of the welding
tool 100 via the second hand grip 118). Compression of the second
spring 114 by such an applied downward force enables the second arm
144 of the housing 104 to move and/or slide toward the second leg
170 of the stabilization foot 106 and/or, more generally, enables
the housing 104 to move and/or slide toward the stabilization foot
106.
[0070] The cap 120 of the welding tool 100 is located and/or
positioned within the first cavity 410 of the central portion 132
of the housing 104, and is configured to close off the upper end of
the first cavity 410. As can be seen in FIG. 4, the cap 120
includes an example upper (e.g., top) end 414, an example lower
(e.g., bottom) end 416 located opposite the upper end 414, and an
example sidewall 418 extending between the upper end 414 and the
lower end 416. The upper end 414 of the cap 120 is oriented toward
the upper end 134 of the central portion 132 of the housing 104,
and the lower end 416 of the cap 120 is oriented toward the lower
end 136 of the central portion 132 of the housing 104. In some
examples, the sidewall 418 of the cap 120 can include threads
configured to mate with a threaded portion of the first cavity 410
of the central portion 132 of the housing 104 to rigidly and/or
fixedly couple the cap 120 to the central portion 132 of the
housing 104. In the illustrated example of FIGS. 1-8, the sidewall
418 of the cap 120 has a circular cross-sectional shape and/or
area. In other examples, the sidewall 418 of the cap 120 can have a
different cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0071] Referring to FIG. 5, the cap 120 can be seen to include an
example opening 510. The opening 510 of the cap 120 extends from
the upper end 414 of the cap 120 through to the lower end 416 of
the cap 120 in a direction parallel to and coaxially aligned with
central axis 140 of the central portion 132 of the housing 104. The
opening 510 of the cap 120 is configured to receive a portion of
the ultrasonic exciter 130 of the welding tool 100 such that the
received portion of the ultrasonic exciter 130 is circumscribed
and/or otherwise bounded by the cap 120, as further described
below. In some examples, the opening 510 of the cap 120, and/or the
portion of the ultrasonic exciter 130 received therein, is/are
fitted with or carry one or more O-rings configured to create an
air-tight seal between the opening 510 of the cap 120 and the
portion of the ultrasonic exciter 130 received therein. In the
illustrated example of FIGS. 1-8, the opening 510 of the cap 120
has a circular cross-sectional shape and/or area. In other
examples, the opening 510 of the cap 120 can have a different
cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0072] The first air pressure conduit 122 and the second air
pressure conduit 124 of the welding tool 100 respectively carry
pressurized air that is selectively and/or controllably supplied to
the first air pressure conduit 122 and/or the second air pressure
conduit 124 to control movement and/or the position of the
compaction foot 302 of the welding tool 100. In the illustrated
example of FIGS. 1-8, the first air pressure conduit 122 and the
second air pressure conduit 124 respectively extend through the
sidewall 138 of the central portion 132 of the housing 104 into the
second cavity 412 of the central portion 132 of the housing 104. As
further described below, the first air pressure conduit 122 extends
into an upper region of the second cavity 412 located and/or
positioned above an outwardly-extending flange of the compaction
foot 302, and the second air pressure conduit 124 extends into a
lower region of the second cavity 412 located and/or positioned
below the outwardly-extending flange of the compaction foot 302.
Pressurized air supplied via the first air pressure conduit 122
causes the compaction foot 302 to move toward the stabilization
foot 106. Pressurized air supplied via the second air pressure
conduit 124 causes the compaction foot 302 to move away from the
stabilization foot 106.
[0073] The third air pressure conduit 126 and the fourth air
pressure conduit 128 of the welding tool 100 respectively carry
pressurized air that is selectively and/or controllably supplied to
the third air pressure conduit 126 and/or the fourth air pressure
conduit 128 to control movement and/or the position of the air
cylinder 402 and/or the welder 304 of the welding tool 100. In the
illustrated example of FIGS. 1-8, the third air pressure conduit
126 extends through the cap 120 into the first cavity 410 of the
central portion 132 of the housing 104, and the fourth air pressure
conduit 128 extends through the sidewall 138 of the central portion
132 of the housing 104 into the first cavity 410 of the central
portion 132 of the housing 104. As further described below, the
third air pressure conduit 126 extends into an upper region of the
first cavity 410 located and/or positioned above a head of the air
cylinder 402, and the fourth air pressure conduit 128 extends into
a lower region of the first cavity 410 located and/or positioned
below the head of the air cylinder 402. Pressurized air supplied
via the third air pressure conduit 126 causes the air cylinder 402
and/or the welder 304 to move toward the stabilization foot 106.
Pressurized air supplied via the fourth air pressure conduit 128
causes the air cylinder 402 and/or the welder 304 to move away from
the stabilization foot 106.
[0074] The compaction foot 302 of the welding tool 100 is
configured to engage, compact, and/or debulk one or more
thermoplastic part(s) of a thermoplastic composite layup prior to,
during and/or following a welding operation to be performed using
the welding tool 100. As can be seen in FIG. 4, the compaction foot
302 includes an example upper (e.g., top) end 420, an example lower
(e.g., bottom) end 422 located opposite the upper end 420, an
example sidewall 424 extending between the upper end 420 and the
lower end 422, and an example central axis 426. The upper end 420
of the compaction foot 302 is oriented away from the stabilization
foot 106, and the lower end 422 of the compaction foot 302 is
oriented toward the stabilization foot 106. The central axis 426 of
the compaction foot 302 is parallel to and coaxially aligned with
the central axis 140 of the central portion 132 of the housing 104,
and/or parallel to and coaxially aligned with the central axis 166
of the base 158 of the stabilization foot 106. In the illustrated
example of FIGS. 1-8, the sidewall 424 of the compaction foot 302
has a circular cross-sectional shape and/or area. In other
examples, the sidewall 424 of the compaction foot 302 can have a
different cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0075] In some examples, the sidewall 424 of the compaction foot
302 contacts and/or engages an O-ring carried by the first
inwardly-extending flange 406 of the central portion 132 of the
housing 104, with the O-ring creating an air-tight seal between the
sidewall 424 of the compaction foot 302 and the first
inwardly-extending flange 406 of the central portion 132 of the
housing 104. In some examples, the sidewall 424 of the compaction
foot 302 contacts and/or engages an O-ring carried by the second
inwardly-extending flange 408 of the central portion 132 of the
housing 104, with the O-ring creating an air-tight seal between the
sidewall 424 of the compaction foot 302 and the second
inwardly-extending flange 408 of the central portion 132 of the
housing 104. In some examples, the sidewall 424 of the compaction
foot 302 carries an O-ring that contacts and/or engages a neck of
the air cylinder 402, with the O-ring creating an air-tight seal
between the sidewall 424 of the compaction foot 302 and the neck of
the air cylinder 402.
[0076] As can be seen in FIG. 4, the compaction foot 302 further
includes an example opening 428 defined by the sidewall 424. The
opening 428 of the compaction foot 302 extends from the upper end
420 of the compaction foot 302 through to the lower end 422 of the
compaction foot 302 in a direction parallel to and coaxially
aligned with the central axis 426. The opening 428 of the
compaction foot 302 is configured to receive one or more portion(s)
of the welder 304 and/or the air cylinder 402, such that the
received portion(s) of the welder 304 and/or the air cylinder 402
is/are circumscribed and/or otherwise bounded by the sidewall 424
of the compaction foot 302, as further described below. In the
illustrated example of FIGS. 1-8, the opening 428 of the compaction
foot 302 has a circular cross-sectional shape and/or area. In other
examples, the opening 428 of the compaction foot 302 can have a
different cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0077] As can be seen in FIG. 4, the compaction foot 302 further
includes a first example outwardly-extending flange 430 located at
and/or proximate to the upper end 420 of the compaction foot 302
and extending outwardly from the sidewall 424 of the compaction
foot 302, a second example outwardly-extending flange 432 located
between the upper end 420 and the lower end 422 of the compaction
foot 302 and extending outwardly from the sidewall 424 of the
compaction foot 302, and an example inwardly-extending flange 434
located at and/or proximate to the lower end 422 of the compaction
foot 302 and extending inwardly from the sidewall 424 of the
compaction foot 302.
[0078] The first outwardly-extending flange 430 of the compaction
foot 302 is located within the first cavity 410 of the opening 404
of the central portion 132 of the housing 104. The first
outwardly-extending flange 430 of the compaction foot 302 provides
a downward mechanical stop that is engageable with the first
inwardly-extending flange 406 of the sidewall 138 of the central
portion 132 of the housing 104 to prevent the compaction foot 302
from moving downward (e.g., toward and/or past the stabilization
foot 106) beyond a configured distance. In some examples, the first
outwardly-extending flange 430 of the compaction foot 302 can be
removably coupled (e.g., via a threaded connection) to the sidewall
424 of the compaction foot 302 to facilitate positioning and/or
securing the compaction foot 302 within the central portion 132 of
the housing 104 during assembly of the welding tool 100. In the
illustrated example of FIGS. 1-8, the first outwardly-extending
flange 430 of the compaction foot 302 has a circular
cross-sectional shape and/or area. In other examples, the first
outwardly-extending flange 430 of the compaction foot 302 can have
a different cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0079] The second outwardly-extending flange 432 of the compaction
foot 302 is located and/or positioned within the second cavity 412
of the opening 404 of the central portion 132 of the housing 104,
and/or between the first inwardly-extending flange 406 and the
second inwardly-extending flange 408 of the central portion 132 of
the housing 104. As can be seen in FIG. 4, the second
outwardly-extending flange 432 of the compaction foot 302 carries
an example O-ring 436 that creates an air-tight seal between the
second outwardly-extending flange 432 of the compaction foot 302
and the sidewall 138 of the central portion 132 of the housing 104.
In this regard, the second outwardly-extending flange 432 and the
O-ring 436 is/are located and/or positioned between the first air
pressure conduit 122 and the second air pressure conduit 124 of the
welding tool 100. Pressurized air supplied via the first air
pressure conduit 122 enters an upper region of the second cavity
412 of the central portion 132 of the housing 104 located and/or
positioned above the second outwardly-extending flange 432 and/or
above the O-ring 436 of the compaction foot 302, and causes the
compaction foot 302 to move toward and/or past the stabilization
foot 106. Pressurized air supplied via the second air pressure
conduit 124 enters a lower region of the second cavity 412 of the
central portion 132 of the housing 104 located and/or positioned
below the second outwardly-extending flange 432 and/or below the
O-ring 436 of the compaction foot 302, and causes the compaction
foot 302 to move away from the stabilization foot 106. In the
illustrated example of FIGS. 1-8, the second outwardly-extending
flange 432 of the compaction foot 302 has a circular
cross-sectional shape and/or area. In other examples, the second
outwardly-extending flange 432 of the compaction foot 302 can have
a different cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0080] As can be seen in FIG. 3, the inwardly-extending flange 434
of the compaction foot 302 forms an example compaction surface 318
that is configured to engage, compact and/or debulk one or more
thermoplastic part(s) of a thermoplastic composite layup. In the
illustrated example of FIGS. 1-8, the compaction surface 318 of the
compaction foot 302 is substantially flat and/or planar. In other
examples, the compaction surface 318 of the compaction foot 302 can
alternatively be curved (e.g., non-planar), contoured, or otherwise
shaped to support and/or complement an associated geometry of one
or more thermoplastic part(s) of a thermoplastic composite layup.
In the illustrated example of FIGS. 1-8, the inwardly-extending
flange 434 and the compaction surface 318 of the compaction foot
302 each have a circular cross-sectional shape and/or area. In
other examples, the inwardly-extending flange 434 and/or the
compaction surface 318 of the compaction foot 302 can have a
different cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0081] The air cylinder 402 of the welding tool 100 is configured
to move the welder 304 of the welding tool 100 relative to the
housing 104 of the welding tool 100, relative to the stabilization
foot 106 of the welding tool 100, and/or relative to the compaction
foot 302 of the welding tool 100, with any and/or all such
movements being in conjunction with a welding operation and/or
process to be performed using the welding tool 100. As can be seen
in FIG. 4, the air cylinder 402 includes an example upper (e.g.,
top) end 438, an example lower (e.g., bottom) end 440 located
opposite the upper end 438, an example sidewall 442 extending
between the upper end 438 and the lower end 440, and an example
central axis 444. The upper end 438 of the air cylinder 402 is
oriented away from the stabilization foot 106, and the lower end
440 of the air cylinder 402 is oriented toward the stabilization
foot 106. The central axis 444 of the air cylinder 402 is parallel
to and coaxially aligned with the central axis 140 of the central
portion 132 of the housing 104, parallel to and coaxially aligned
with the central axis 166 of the base 158 of the stabilization foot
106, and/or parallel to and coaxially aligned with the central axis
426 of the compaction foot 302. In the illustrated example of FIGS.
1-8, the sidewall 442 of the air cylinder 402 has a circular
cross-sectional shape and/or area. In other examples, the sidewall
442 of the air cylinder 402 can have a different cross-sectional
shape and/or area (e.g., a non-circular cross-sectional shape
and/or area, a differently sized cross-sectional shape and/or area,
etc.).
[0082] Referring to FIG. 5, the air cylinder 402 can be seen to
include an example opening 512 defined by the sidewall 442. The
opening 512 of the air cylinder 402 extends from the upper end 438
of the air cylinder 402 through to the lower end 440 of the air
cylinder 402 in a direction parallel to and coaxially aligned with
the central axis 444. The opening 512 of the air cylinder 402 is
configured to receive one or more portion(s) of the welder 304
and/or the ultrasonic exciter 130 of the welding tool 100, such
that the received portion(s) of the welder 304 and/or the
ultrasonic exciter 130 is/are circumscribed and/or otherwise
bounded by the sidewall 442 of the air cylinder 402, as further
described below. In the illustrated example of FIGS. 1-8, the
opening 512 of the air cylinder 402 has a circular cross-sectional
shape and/or area. In other examples, the opening 512 of the air
cylinder 402 can have a different cross-sectional shape and/or area
(e.g., a non-circular cross-sectional shape and/or area, a
differently sized cross-sectional shape and/or area, etc.).
[0083] As can be seen in FIG. 4, the air cylinder 402 further
includes an example head 446 located at and/or proximate to the
upper end 438 of the air cylinder 402. The head 446 of the air
cylinder 402 is located within the first cavity 410 of the opening
404 of the central portion 132 of the housing 104, and/or between
the cap 120 of the welding tool 100 and the first
inwardly-extending flange 406 of the central portion 132 of the
housing 104 of the welding tool 100. As can be seen in FIG. 4, the
head 446 of the air cylinder 402 carries one or more example
O-ring(s) 448 that individually and/or collectively create an
air-tight seal between the head 446 of the air cylinder 402 and the
sidewall 138 of the central portion 132 of the housing 104. In this
regard, the head 446 and the O-ring(s) 448 is/are located and/or
positioned between the third air pressure conduit 126 and the
fourth air pressure conduit 128 of the welding tool 100.
Pressurized air supplied via the third air pressure conduit 126
enters an upper region of the first cavity 410 of the central
portion 132 of the housing 104 located and/or positioned above the
head 446 and/or above the O-ring(s) 448 of the air cylinder 402,
and causes the air cylinder 402 to move toward the stabilization
foot 106. Pressurized air supplied via the fourth air pressure
conduit 128 enters a lower region of the first cavity 410 of the
central portion 132 of the housing 104 located and/or positioned
below the head 446 and/or below the O-ring(s) 448 of the air
cylinder 402, and causes the air cylinder 402 to move away from the
stabilization foot 106. In the illustrated example of FIGS. 1-8,
the head 446 of the air cylinder 402 has a circular cross-sectional
shape and/or area. In other examples, the head 446 of the air
cylinder 402 can have a different cross-sectional shape and/or area
(e.g., a non-circular cross-sectional shape and/or area, a
differently sized cross-sectional shape and/or area, etc.).
[0084] As can be seen in FIG. 4, the air cylinder 402 further
includes an example neck 450 located at and/or proximate to the
lower end 440 of the air cylinder 402. The neck 450 of the air
cylinder 402 is configured to be slidably received within the
opening 428 of the compaction foot 302 such that the air cylinder
402 is movable relative to the stabilization foot 106 independently
from the compaction foot 302 moving relative to the stabilization
foot 106, and vice-versa. In the illustrated example of FIGS. 1-8,
the neck 450 of the air cylinder 402 has a circular cross-sectional
shape and/or area. In other examples, the neck 450 of the air
cylinder 402 can have a different cross-sectional shape and/or area
(e.g., a non-circular cross-sectional shape and/or area, a
differently sized cross-sectional shape and/or area, etc.).
[0085] The welder 304 of the welding tool 100 is configured to weld
(e.g., tack weld) a thermoplastic part to one or more other
thermoplastic part(s) of a thermoplastic composite layup in
conjunction with a welding operation to be performed using the
welding tool 100, during a compaction operation to be performed
using the welding tool 100, and/or during a stabilization operation
to be performed using the welding tool 100. The welder 304 can be
implemented as an ultrasonic welder that is powered, controlled
and/or operated by the ultrasonic exciter 130 and/or by a power
supply operatively coupled to the ultrasonic exciter 130. In some
examples, a power supply configured to power the ultrasonic exciter
130 and/or the welder 304 can be mounted on the welding tool 100.
In other examples, the power supply can alternatively be located
remotely from the welding tool 100. In some examples, the power
supply is adjustable such that the ultrasonic exciter 130 and/or
the welder 304 can operate at different (e.g., adjustable) power
settings depending upon material and/or specification requirements
associated with the welding operation to be performed.
[0086] As can be seen in FIG. 4, the welder 304 includes an example
horn 452, an example welding tip 454, and an example central axis
456. The central axis 456 of the welder 304 is parallel to and
coaxially aligned with the central axis 140 of the central portion
132 of the housing 104, parallel to and coaxially aligned with the
central axis 166 of the base 158 of the stabilization foot 106,
parallel to and coaxially aligned with the central axis 426 of the
compaction foot 302, and/or parallel to and coaxially aligned with
the central axis 444 of the air cylinder 402. In the illustrated
example of FIGS. 1-8, the welder 304 has a circular cross-sectional
shape and/or area. In other examples, the welder 304 can have a
different cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0087] The horn 452 of the welder 304 is located and/or positioned
within the opening 512 and/or the neck 450 of the air cylinder 402
such that the horn 452 and/or, more generally, the welder 304 is
rigidly and/or fixedly coupled to the air cylinder 402. In some
examples, the horn 452 can include threads configured to mate with
a threaded portion of the opening 512 of the air cylinder 402 to
rigidly and/or fixedly couple the horn 452 and/or, more generally,
the welder 304 to the air cylinder 402. In other examples, the horn
452 can additionally or alternatively include threads configured to
mate with a threaded portion of the ultrasonic exciter 130 to
rigidly and/or fixedly couple the horn 452 and/or, more generally,
the welder 304 to the ultrasonic exciter 130. In the illustrated
example of FIGS. 1-8, the horn 452 has a circular cross-sectional
shape and/or area. In other examples, the horn 452 can have a
different cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0088] As can be seen in FIG. 3, the welding tip 454 of the welder
304 forms an example welding surface 320 that is configured to weld
a thermoplastic part to one or more other thermoplastic part(s) of
a thermoplastic composite layup. In the illustrated example of
FIGS. 1-8, the welding surface 320 of the welding tip 454 is
substantially flat and/or planar. In other examples, the welding
surface 320 of the welding tip 454 can alternatively be curved
(e.g., non-planar), contoured, or otherwise shaped. In the
illustrated example of FIGS. 1-8, the welding tip 454 and the
welding surface 320 each have a circular cross-sectional shape
and/or area. In other examples, the welding tip 454 and/or the
welding surface 320 can have a different cross-sectional shape
and/or area (e.g., a non-circular cross-sectional shape and/or
area, a differently sized cross-sectional shape and/or area,
etc.).
[0089] The ultrasonic exciter 130 of the welding tool 100 is
configured to generate ultrasonic signals (e.g., via a generator
and a transducer of the ultrasonic exciter 130), and to
mechanically transfer the generated ultrasonic signals to the horn
452 of the welder 304. Referring to FIG. 5, the ultrasonic exciter
130 can be seen to include a first example portion 514 located
and/or positioned within the opening 510 of the cap 120, and a
second example portion 516 located and/or positioned within the
opening 512 of the air cylinder 402. The ultrasonic exciter 130 is
movable along the central axis 140 of the central portion 132 of
the housing 104 in unison with movement of the air cylinder 402
and/or movement of the welder 304. In the illustrated example of
FIGS. 1-8, the ultrasonic exciter 130 has a circular
cross-sectional shape and/or area. In other examples, the
ultrasonic exciter 130 can have a different cross-sectional shape
and/or area (e.g., a non-circular cross-sectional shape and/or
area, a differently sized cross-sectional shape and/or area,
etc.).
[0090] In the illustrated example of FIGS. 1-8, the welding surface
320 of the welder 304, the compaction surface 318 of the compaction
foot 302, and the stabilization surface 306 of the stabilization
foot 106 are concentrically located and/or positioned relative to
one another, with the compaction surface 318 circumscribing the
welding surface 320, and the stabilization surface 306
circumscribing the compaction surface 318. When the welding tool
100 is placed on a first thermoplastic part of a thermoplastic
composite layup, the stabilization surface 306 is configured to
provide and/or impart a first pressure and/or a first force to the
first thermoplastic part, over an area consistent with the geometry
of the stabilization surface 306, to stabilize the first
thermoplastic part relative to one or more other thermoplastic
part(s) of the thermoplastic composite layup. The compaction
surface 318 in turn is configured to provide and/or impart a second
pressure and/or a second force to the first thermoplastic part,
over an area consistent with the geometry of the compaction surface
318, to compact and/or debulk the first thermoplastic part and/or
one or more other thermoplastic part(s) of the thermoplastic
composite layup. The welding surface 320 in turn is configured to
provide and/or impart a third pressure and/or a third force to the
first thermoplastic part, over an area consistent with the geometry
of the welding surface 320, to weld (e.g., tack weld) the first
thermoplastic part to one or more other thermoplastic part(s) of
the thermoplastic composite layup.
[0091] The housing 104 of the welding tool 100 is movable along the
central axis 140 between a neutral (e.g., uncompressed) position of
the housing 104 and a compressed position of the housing 104.
Movement of the housing 104 occurs relative to the stabilization
foot 106. For example, the housing 104 can be moved, along the
central axis 140, from an example neutral position of the housing
104 (e.g., a position in which the housing 104 is separated from
the stabilization foot 106 by a first distance) associated with the
first configuration 102 of the welding tool 100 shown in FIGS. 1-5
to an example compressed position of the housing 104 (e.g., a
position in which the housing 104 is separated from the
stabilization foot 106 by a second distance less than the first
distance associated with the neutral position of the housing 104)
associated with the second configuration 602 of the welding tool
100 shown in FIG. 6, the third configuration 702 of the welding
tool 100 shown in FIG. 7, and/or the fourth configuration 802 of
the welding tool 100 shown in FIG. 8. The first spring 112 and/or
the second spring 114 of the welding tool 100 has/have a first
length when the housing 104 is in the neutral position, and a
second length less than the first length when the housing 104 is in
the compressed position. In some examples, the central portion 132
of the housing 104 contacts the base 158 of the stabilization foot
106 when the housing 104 is in the compressed position.
[0092] The housing 104 can be moved along the central axis 140 from
and/or into a variety of different compressed positions. In other
words, the housing 104 can have variable and/or adjustable
compressed positions. For example, the compressed position of the
housing 104 can vary based on the extent and/or degree of force
that may be required of the stabilization surface 306 and/or the
stabilization foot 106 to stabilize a first thermoplastic part
relative to one or more other thermoplastic part(s) of a
thermoplastic composite layup. In some examples, the stabilization
surface 306 of the stabilization foot 106 can stabilize a first
thermoplastic part relative to a second thermoplastic part while
the compaction surface 318 of the compaction foot 302 compacts
and/or debulks the first thermoplastic part, and/or while the
welding surface 320 of the welder 304 welds the first thermoplastic
part to the second thermoplastic part. In such examples, once the
stabilization operation is complete, the housing 104 can retract
back from the compressed position of the housing 104 associated
with the second configuration 602 of the welding tool 100 shown in
FIG. 6, the third configuration 702 of the welding tool 100 shown
in FIG. 7, and/or the fourth configuration 802 of the welding tool
100 shown in FIG. 8, to the neutral position of the housing 104
associated with the first configuration 102 of the welding tool 100
shown in FIGS. 1-5.
[0093] In the illustrated example of FIGS. 1-8, the above-described
movements of the housing 104 occur and/or are performed manually by
a human operator of the welding tool 100, with the housing 104
being forced toward the stabilization foot 106 in response to the
human operator gripping and/or grasping the first hand grip 116
and/or the second hand grip 118 of the welding tool 100 and
applying a downward force thereto. In this regard, movement of the
housing 104 toward the stabilization foot 106 occurs when the
operator-applied downward force is sufficiently powerful to
overcome the spring force(s) generated by the first spring 112
and/or the second spring 114 of the welding tool 100 that bias the
housing 104 away from the stabilization foot 106. When the
stabilization surface 306 of the stabilization foot 106 is placed
in contact with a thermoplastic part of a thermoplastic composite
layup, an increase to the operator-applied downward force produces
a corresponding and/or associated increase to the force by which
the stabilization surface 306 of the stabilization foot 106
stabilizes the thermoplastic part.
[0094] The compaction foot 302 of the welding tool 100 is movable
(e.g., independent of movement of the welder 304) along the central
axis 426 between a retracted position of the compaction foot 302
and an extended position of the compaction foot 302. In some
examples, movement of the compaction foot 302 occurs relative to
the housing 104, relative to the stabilization foot 106, and/or
relative to the welder 304. For example, the compaction surface 318
and/or, more generally, the compaction foot 302 can be moved, along
the central axis 426, from an example retracted position of the
compaction foot 302 (e.g., a position in which the compaction
surface 318 of the compaction foot 302 is located above the
stabilization surface 306 of the stabilization foot 106) associated
with the first configuration 102 of the welding tool 100 shown in
FIGS. 1-5, and/or the second configuration 602 of the welding tool
100 shown in FIG. 6, to an example extended position of the
compaction foot 302 (e.g., a position in which the compaction
surface 318 of the compaction foot 302 is flush with or located
below the stabilization surface 306 of the stabilization foot 106)
associated with the third configuration 702 of the welding tool 100
shown in FIG. 7, and/or the fourth configuration 802 of the welding
tool 100 shown in FIG. 8.
[0095] The compaction surface 318 and/or, more generally, the
compaction foot 302 can be moved along the central axis 426 from
and/or into a variety of different extended positions. In other
words, the compaction surface 318 and/or the compaction foot 302
can have variable and/or adjustable extended positions. For
example, the extended position of the compaction surface 318 and/or
the compaction foot 302 can vary based on the extent and/or degree
of extension that may be required of the compaction surface 318
and/or the compaction foot 302 to compact and/or debulk a first
thermoplastic part relative to one or more other thermoplastic
part(s) of a thermoplastic composite layup. In some examples, the
compaction surface 318 of the compaction foot 302 can compact
and/or debulk a first thermoplastic part relative to a second
thermoplastic part while the stabilization surface 306 of the
stabilization foot 106 stabilizes the first thermoplastic part,
and/or while the welding surface 320 of the welder 304 welds the
first thermoplastic part to the second thermoplastic part. In such
examples, once the compaction operation is complete, the compaction
surface 318 of the compaction foot 302 can retract back from the
extended position of the compaction foot 302 associated with the
third configuration 702 of the welding tool 100 shown in FIG. 7,
and/or the fourth configuration 802 of the welding tool 100 shown
in FIG. 8, to the retracted position of the compaction foot 302
associated with the first configuration 102 of the welding tool 100
shown in FIGS. 1-5, and/or the second configuration 602 of the
welding tool 100 shown in FIG. 6.
[0096] In the illustrated example of FIGS. 1-8, the above-described
movements of the compaction surface 318 and/or, more generally, the
compaction foot 302 occur and/or are performed in an automated
manner, with the compaction foot 302 being driven and/or controlled
by pressurized air delivered in a regulated manner to the
compaction foot 302 through the first air pressure conduit 122
and/or the second air pressure conduit 124. The pressure and/or the
force at which the compaction foot 302 operates (e.g., the pressure
and/or the force at which the compaction foot 302 compacts a first
thermoplastic part) can accordingly be controlled and/or adjusted
via the regulated supply of pressurized air delivered to the
compaction foot 302. The period of time (e.g., the duration) for
which the compaction surface 318 and/or, more generally, the
compaction foot 302 remains in any particular position (e.g., any
retracted position or any extended position) can also be controlled
and/or adjusted via the regulated supply of pressurized air to
compaction foot 302. In some examples, the pressure and/or the
force at which the compaction foot 302 operates, and/or the period
of time for which the compaction surface 318 and/or, more
generally, the compaction foot 302 remains in any particular
position can be automatically determined and/or implemented based
on material and/or specification requirements associated with the
compaction operation and/or a welding operation to be performed. In
some examples, the automated delivery and/or regulated supply of
pressurized air to the compaction foot 302 can be initiated in
response to a human operator of the welding tool 100 actuating a
user input device (e.g., a button, a switch, a foot pedal, etc.)
that is operatively coupled to the welding tool 100 and/or
operatively coupled to the supply source of the pressurized air. In
other examples, the automated delivery and/or regulated supply of
pressurized air to the compaction foot 302 can alternatively be
initiated in response to a human operator of the welding tool 100
maintaining the housing 104 in a compressed position for a
predetermined time period.
[0097] The welder 304 of the welding tool 100 is movable (e.g.,
independent of movement of the compaction foot 302) along the
central axis 456 between a retracted position of the welder 304 and
an extended position of the welder 304. In some examples, movement
of the welder 304 occurs relative to the housing 104, relative to
the stabilization foot 106, and/or relative of the compaction foot
302. For example, the welding surface 320 and/or, more generally,
the welder 304 can be moved, along the central axis 456, from an
example retracted position of the welder 304 (e.g., a position in
which the welding surface 320 of the welder 304 is located above
the stabilization surface 306 of the stabilization foot 106, and/or
above the compaction surface 318 of the compaction foot 302)
associated with the first configuration 102 of the welding tool 100
shown in FIGS. 1-5, the second configuration 602 of the welding
tool 100 shown in FIG. 6, and/or the third configuration 702 of the
welding tool 100 shown in FIG. 7, to an example extended position
of the welder 304 (e.g., a position in which the welding surface
320 of the welder 304 is flush with or located below the
stabilization surface 306 of the stabilization foot 106, and/or
flush with or located below the compaction surface 318 of the
compaction foot 302) associated with the fourth configuration 802
of the welding tool 100 shown in FIG. 8.
[0098] The welding surface 320 and/or, more generally, the welder
304 can be moved along the central axis 456 from and/or into a
variety of different extended positions. In other words, the
welding surface 320 and/or the welder 304 can have variable and/or
adjustable extended positions. For example, the extended position
of the welding surface 320 and/or the welder 304 can vary based on
the extent and/or degree of extension that may be required of the
welding surface 320 and/or the welder 304 to weld (e.g., tack weld)
a first thermoplastic part to one or more other thermoplastic
part(s) of a thermoplastic composite layup. In some examples, the
welding surface 320 of the welder 304 can weld a first
thermoplastic part to a second thermoplastic part while the
stabilization surface 306 of the stabilization foot 106 stabilizes
the first thermoplastic part, and/or while the compaction surface
318 of the compaction foot 302 compacts the first thermoplastic
part. In such examples, once the welding operation is complete, the
welding surface 320 of the welder 304 can retract back from the
extended position of the welder 304 associated with the fourth
configuration 802 of the welding tool 100 shown in FIG. 8 to the
retracted position of the welder 304 associated with the first
configuration 102 of the welding tool 100 shown in FIGS. 1-5, the
second configuration 602 of the welding tool 100 shown in FIG. 6,
and/or the third configuration 702 of the welding tool 100 shown in
FIG. 7.
[0099] In the illustrated example of FIGS. 1-8, the above-described
movements of the welding surface 320 and/or, more generally, the
welder 304 occur and/or are performed in an automated manner, with
the welder 304 being driven and/or controlled by pressurized air
delivered in a regulated manner to the air cylinder 402 through the
third air pressure conduit 126 and/or the fourth air pressure
conduit 128. The pressure and/or the force at which the welder 304
operates (e.g., the pressure and/or the force at which the welder
304 welds a first thermoplastic part to a second thermoplastic
part) can accordingly be controlled and/or adjusted via the
regulated supply of pressurized air delivered to the air cylinder
402. The period of time (e.g., the duration) for which the welding
surface 320 and/or, more generally, the welder 304 remains in any
particular position (e.g., any retracted position or any extended
position) can also be controlled and/or adjusted via the regulated
supply of pressurized air to the air cylinder 402. In some
examples, the pressure and/or the force at which the welder 304
operates, and/or the period of time for which the welding surface
320 and/or, more generally, the welder 304 remains in any
particular position can be automatically determined and/or
implemented based on material and/or specification requirements
associated with the welding operation to be performed. In some
examples, the automated delivery and/or regulated supply of
pressurized air to the air cylinder 402 can be initiated in
response to a human operator of the welding tool 100 actuating a
user input device (e.g., a button, a switch, a foot pedal, etc.)
that is operatively coupled to the welding tool 100 and/or
operatively coupled to the supply source of the pressurized air. In
other examples, the automated delivery and/or regulated supply of
pressurized air to the air cylinder 402 can alternatively be
initiated in response to a human operator of the welding tool 100
maintaining the housing 104 in a compressed position for a
predetermined time period.
[0100] When the welding tool 100 of FIGS. 1-8 is in the first
configuration 102 shown in FIGS. 1-5, the housing 104 is in a
neutral (e.g., uncompressed) position, the compaction foot 302 is
in a retracted position, and the welder 304 is in a retracted
position. More specifically, when the welding tool 100 is in the
first configuration 102 shown in FIGS. 1-5, the lower end 136 of
the central portion 132 of the housing 104 is spaced apart from the
upper surface 160 of the base 158 of the stabilization foot 106 by
a first distance, the compaction surface 318 of the compaction foot
302 is located and/or positioned above the stabilization surface
306 of the stabilization foot 106, and the welding surface 320 of
the welder 304 is located and/or positioned above the stabilization
surface 306 of the stabilization foot 106 and/or above the
compaction surface 318 of the compaction foot 302.
[0101] When the welding tool 100 of FIGS. 1-8 is in the second
configuration 602 shown in FIG. 6, the housing 104 is in a
compressed position, the compaction foot 302 is in a retracted
position, and the welder 304 is in a retracted position. More
specifically, when the welding tool 100 is in the second
configuration 602 shown in FIG. 6, the lower end 136 of the central
portion 132 of the housing 104 is spaced apart from the upper
surface 160 of the base 158 of the stabilization foot 106 by a
second distance that is less than the first distance described
above in connection with the first configuration 102 of FIGS. 1-5.
In the illustrated example of FIG. 6, the lower end 136 of the
central portion 132 of the housing 104 contacts the upper surface
160 of the base 158 of the stabilization foot 106, thereby making
the second distance effectively zero. In other examples, the second
distance can be greater than zero, but less than the first distance
associated with the first configuration 102 of FIGS. 1-5. When the
welding tool 100 is in the second configuration 602 shown in FIG.
6, the compaction surface 318 of the compaction foot 302 is located
and/or positioned above the stabilization surface 306 of the
stabilization foot 106, and the welding surface 320 of the welder
304 is located and/or positioned above the stabilization surface
306 of the stabilization foot 106 and/or above the compaction
surface 318 of the compaction foot 302.
[0102] When the welding tool 100 of FIGS. 1-8 is in the third
configuration 702 shown in FIG. 7, the housing 104 is in a
compressed position, the compaction foot 302 is in an extended
position, and the welder 304 is in a retracted position. More
specifically, when the welding tool 100 is in the third
configuration 702 shown in FIG. 7, the lower end 136 of the central
portion 132 of the housing 104 is spaced apart from the upper
surface 160 of the base 158 of the stabilization foot 106 by the
second distance described above in connection with the second
configuration 602 of FIG. 6. When the welding tool 100 is in the
third configuration 702 shown in FIG. 7, the compaction surface 318
of the compaction foot 302 is located and/or positioned flush with
or below (e.g., slightly below) the stabilization surface 306 of
the stabilization foot 106, and the welding surface 320 of the
welder 304 is located and/or positioned above the stabilization
surface 306 of the stabilization foot 106 and/or above the
compaction surface 318 of the compaction foot 302.
[0103] When the welding tool 100 of FIGS. 1-8 is in the fourth
configuration 802 shown in FIG. 8, the housing 104 is in a
compressed position, the compaction foot 302 is in an extended
position, and the welder 304 is in an extended position. More
specifically, when the welding tool 100 is in the fourth
configuration 802 shown in FIG. 8, the lower end 136 of the central
portion 132 of the housing 104 is spaced apart from the upper
surface 160 of the base 158 of the stabilization foot 106 by the
second distance described above in connection with the second
configuration 602 of FIG. 6. When the welding tool 100 is in the
fourth configuration 802 shown in FIG. 8, the compaction surface
318 of the compaction foot 302 is located and/or positioned flush
with or below (e.g., slightly below) the stabilization surface 306
of the stabilization foot 106, as described above in connection
with the third configuration 702 of FIG. 7. When the welding tool
100 is in the fourth configuration 802 shown in FIG. 8, the welding
surface 320 of the welder 304 is located and/or positioned flush
with or below (e.g., slightly below) the stabilization surface 306
of the stabilization foot 106, and/or flush with or below (e.g.,
slightly below) the compaction surface 318 of the compaction foot
302.
[0104] FIGS. 9-15 illustrate example stages (e.g., a first example
stage 902, a second example stage 1002, a third example stage 1102,
a fourth example stage 1202, a fifth example stage 1302, a sixth
example stage 1402, and a seventh example stage 1502) of an example
process 900 to be implemented via the welding tool 100 of FIGS. 1-8
to weld a first example thermoplastic part 904 to a second example
thermoplastic part 906. As further described below, the process 900
includes stabilizing the first thermoplastic part 904 relative to
the second thermoplastic part 906, compacting and/or debulking the
stabilized first and second thermoplastic parts 904, 906, and
welding the compacted first and second thermoplastic parts 904, 906
to one another in the course of forming a thermoplastic composite
layup including at least the first thermoplastic part 904 and the
second thermoplastic part 906.
[0105] The first and second thermoplastic parts 904, 906 of FIGS.
9-15 can respectively be of any size, shape, and/or configuration
(e.g., a substantially flat and/or planar shape, a tapered shape, a
sloped shape, a curved shape, a contoured shape, etc.). In some
examples, the first thermoplastic part, 904, the second
thermoplastic part 906, and/or one or more other thermoplastic
part(s) of an example thermoplastic composite layup 908 including
the first thermoplastic part 904, the second thermoplastic part
906, and/or the one or more other thermoplastic part(s) can include
one or more ply drop(s) and/or one or more area(s) of significant
bulk. In some examples, the first thermoplastic part 904 and the
second thermoplastic part 906 are respectively single-ply
thermoplastic parts. In other examples, the first thermoplastic
part 904 and/or the second thermoplastic part 906 can alternatively
be a multi-ply thermoplastic part, with the multiple plies of the
multi-ply thermoplastic part(s) either being welded together or not
yet welded together. In some examples, the thermoplastic composite
layup 908 may be located and/or positioned on an example layup
table 910 while the process 900 of FIGS. 9-15 is being
performed.
[0106] FIG. 9 illustrates the first stage 902 of the example
process 900. During the first stage 902, the welding tool 100 is
manually placed (e.g., by a human operator of the welding tool 100)
onto the first thermoplastic part 904 such that the stabilization
surface 306 of the stabilization foot 106 contacts at least a
portion of the first thermoplastic part 904. The welding tool 100
is positioned and/or remains positioned in the first configuration
102 of FIGS. 1-5 described above while the first stage 902 is being
performed.
[0107] FIG. 10 illustrates the second stage 1002 of the example
process 900. During the second stage 1002, the housing 104 is
manually moved (e.g., by a human operator of the welding tool 100)
toward the stabilization foot 106 such that the stabilization
surface 306 of the stabilization foot 106 stabilizes the first
thermoplastic part 904 relative to the second thermoplastic part
906. The housing 104 is accordingly moved from a neutral (e.g.,
uncompressed) position to a compressed position in connection with
the second stage 1002 of the process 900. The welding tool 100
transitions from being positioned in the first configuration 102 of
FIGS. 1-5 described above to being positioned in the second
configuration 602 of FIG. 6 described above while the second stage
1002 is being performed.
[0108] FIG. 11 illustrates the third stage 1102 of the example
process 900. During the third stage 1102, the compaction foot 302
is automatically moved (e.g., by a controlled and/or regulated
supply of pressurized air delivered to the compaction foot 302 via
the first air pressure conduit 122 of the welding tool 100) from a
retracted position to an extended position in which the compaction
surface 318 of the compaction foot 302 compacts and/or debulks the
first thermoplastic part 904 and/or the second thermoplastic part
906. The welding tool 100 transitions from being positioned in the
second configuration 602 of FIG. 6 described above to being
positioned in the third configuration 702 of FIG. 7 described above
while the third stage 1102 is being performed.
[0109] FIG. 12 illustrates the fourth stage 1202 of the example
process 900. During the fourth stage 1202, the welder 304 is
automatically moved (e.g., by a controlled and/or regulated supply
of pressurized air delivered to the air cylinder 402 via the third
air pressure conduit 126 of the welding tool 100) from a retracted
position to an extended position in which the welding surface 320
of the welder 304 forms an example weld 1204 that fixedly couples
the first thermoplastic part 904 to the second thermoplastic part
906. The welding tool 100 transitions from being positioned in the
third configuration 702 of FIG. 7 described above to being
positioned in the fourth configuration 802 of FIG. 8 described
above while the fourth stage 1202 is being performed.
[0110] FIG. 13 illustrates the fifth stage 1302 of the example
process 900. During the fifth stage 1302, the welder 304 is
automatically moved (e.g., by a controlled and/or regulated supply
of pressurized air delivered to the air cylinder 402 via the fourth
air pressure conduit 128 of the welding tool 100) from its extended
position back to its retracted position subsequent to (e.g.,
immediately following) the welder 304 forming the weld 1204. The
welding tool 100 transitions from being positioned in the fourth
configuration 802 of FIG. 8 described above to being positioned in
the third configuration 702 of FIG. 7 described above while the
fifth stage 1302 is being performed.
[0111] FIG. 14 illustrates the sixth stage 1402 of the example
process 900. During the sixth stage 1402, the compaction foot 302
is automatically moved (e.g., by a controlled and/or regulated
supply of pressurized air delivered to the compaction foot 302 via
the second air pressure conduit 124 of the welding tool 100) from
its extended position back to its retracted position subsequent to
(e.g., following expiration of a predetermined time period after)
the welder 304 returning from its extended position to its
retracted position in connection with the fifth stage 1302 of the
process 900, and/or subsequent to the weld 1204 cooling. The
welding tool 100 transitions from being positioned in the third
configuration 702 of FIG. 7 described above to being positioned in
the second configuration 602 of FIG. 6 described above while the
sixth stage 1402 is being performed.
[0112] FIG. 15 illustrates the seventh stage 1502 of the example
process 900. During the seventh stage 1502, the housing 104 is
moved (e.g., by a spring force associated with the first spring 112
and/or the second spring 114 of the welding tool 100 in response to
the human operator of the welding tool 100 releasing a
manually-applied force) away from the stabilization foot 106, from
its compressed position to its neutral position. The welding tool
100 transitions from being positioned in the second configuration
602 of FIG. 6 described above to being positioned in the first
configuration 102 of FIGS. 1-5 described above while the seventh
stage 1502 is being performed.
[0113] FIG. 16 is a flowchart representative of an example method
1600 for implementing the example welding tool 100 of FIGS. 1-8 to
weld a first example thermoplastic part to a second example
thermoplastic part. In some examples, the method 1600 can be
implemented in connection with the welding tool 100 being utilized
to perform the example process 900 of FIGS. 9-15 described above.
The method 1600 includes manually placing (e.g., by a human
operator) the welding tool 100 onto a first thermoplastic part
(e.g., the first thermoplastic part 904 of FIGS. 9-15) stacked
above a second thermoplastic part (e.g., the second thermoplastic
part 906 of FIGS. 9-15) (block 1602). For example, the welding tool
100 can be placed on the first thermoplastic part such that the
stabilization surface 306 of the stabilization foot 106 contacts at
least a portion of the first thermoplastic part. The welding tool
100 is positioned and/or remains positioned in the first
configuration 102 of FIGS. 1-5 described above while block 1602 of
the method 1600 is being performed. Following block 1602, the
method 1600 proceeds to block 1604.
[0114] At block 1604, the method 1600 includes manually moving
(e.g., by a human operator) the housing 104 of the welding tool 100
toward the stabilization foot 106 of the welding tool 100 (e.g.,
from a neutral position to a compressed position) to cause the
stabilization surface 306 of the stabilization foot 106 to
stabilize the first thermoplastic part 904 relative to the second
thermoplastic part. The welding tool 100 transitions from being
positioned in the first configuration 102 of FIGS. 1-5 described
above to being positioned in the second configuration 602 of FIG. 6
described above while block 1604 of the method 1600 is being
performed. Following block 1604, the method 1600 proceeds to block
1606.
[0115] At block 1606, the method 1600 includes automatically moving
(e.g., by a controlled and/or regulated supply of pressurized air
delivered to the compaction foot 302 via the first air pressure
conduit 122 of the welding tool 100) the compaction foot 302 of the
welding tool 100 from a retracted position to an extended position
to cause the compaction surface 318 of the compaction foot 302 to
compact and/or debulk the first thermoplastic part and/or the
second thermoplastic part. The welding tool 100 transitions from
being positioned in the second configuration 602 of FIG. 6
described above to being positioned in the third configuration 702
of FIG. 7 described above while block 1606 of the method 1600 is
being performed. Following block 1606, the method 1600 proceeds to
block 1608.
[0116] At block 1608, the method 1600 includes automatically moving
(e.g., by a controlled and/or regulated supply of pressurized air
delivered to the air cylinder 402 via the third air pressure
conduit 126 of the welding tool 100) the welder 304 of the welding
tool 100 from a retracted position to an extended position to cause
the welding surface 320 of the welder 304 to form a weld (e.g., the
weld 1204 of FIGS. 12-15) that fixedly couples the first
thermoplastic part to the second thermoplastic part. The welding
tool 100 transitions from being positioned in the third
configuration 702 of FIG. 7 described above to being positioned in
the fourth configuration 802 of FIG. 8 described above while block
1608 of the method 1600 is being performed. Following block 1608,
the method 1600 proceeds to block 1610.
[0117] At block 1610, the method 1600 includes automatically moving
(e.g., by a controlled and/or regulated supply of pressurized air
delivered to the air cylinder 402 via the fourth air pressure
conduit 128 of the welding tool 100) the welder 304 of the welding
tool 100 from its extended position back to its retracted position
subsequent to (e.g., immediately following) the welder 304 of the
welding tool 100 forming the weld. The welding tool 100 transitions
from being positioned in the fourth configuration 802 of FIG. 8
described above to being positioned in the third configuration 702
of FIG. 7 described above while block 1610 of the method 1600 is
being performed. Following block 1610, the method 1600 proceeds to
block 1612.
[0118] At block 1612, the method 1600 includes automatically moving
(e.g., by a controlled and/or regulated supply of pressurized air
delivered to the compaction foot 302 via the second air pressure
conduit 124 of the welding tool 100) the compaction foot 302 from
its extended position back to its retracted position subsequent to
(e.g., following expiration of a predetermined time period after)
the welder 304 returning from its extended position to its
retracted position in connection with the fifth stage 1302 of the
process 900, and/or subsequent to the weld cooling. The welding
tool 100 transitions from being positioned in the third
configuration 702 of FIG. 7 described above to being positioned in
the second configuration 602 of FIG. 6 described above while block
1612 of the method 1600 is being performed. Following block 1612,
the method 1600 proceeds to block 1614.
[0119] At block 1614, the method 1600 of FIG. 16 includes moving
(e.g., by a spring force associated with the first spring 112
and/or the second spring 114 of the welding tool 100 in response to
the human operator of the welding tool 100 releasing a
manually-applied force) the housing 104 of the welding tool 100
away from the stabilization foot 106 of the welding tool 100, from
its compressed position to its neutral position. The welding tool
100 transitions from being positioned in the second configuration
602 of FIG. 6 described above to being positioned in the first
configuration 102 of FIGS. 1-5 described above while block 1614 of
the method 1600 is being performed. Following block 1614, the
method 1600 ends.
[0120] FIGS. 17-24 are directed to an alternate example welding
tool 1700 constructed in accordance with the teachings of this
disclosure. As described in greater detail below, the welding tool
1700 of FIGS. 17-24 is generally structured, and generally
operates, in a manner having similarities to the structure and
operation of the welding tool 100 of FIGS. 1-8 described above. In
this regard, the welding tool 1700 of FIGS. 17-24, much like the
welding tool 100 of FIGS. 1-8, includes a stabilization foot, a
housing that is configured to be manually moved relative to the
stabilization foot, a compaction foot that is configured to be
moved relative to the stabilization foot, and a welder that is
configured to be automatically moved relative to the stabilization
foot. The welding tool 1700 of FIGS. 17-24 differs from the welding
tool 100 of FIGS. 1-8 primarily in that the compaction foot of the
welding tool 1700 is configured to be manually moved (via manual
movement of the housing) relative to the stabilization foot,
whereas the compaction foot of the welding tool 100 is instead
configured to be automatically moved relative to the stabilization
foot.
[0121] FIG. 17 is a perspective view of an example welding tool
1700 shown in a first example configuration 1702. FIG. 18 is a side
view of the welding tool 1700 shown in the first configuration
1702. FIG. 19 is a bottom view of the welding tool 1700 shown in
the first configuration 1702. FIG. 20 is a partial cutaway view of
the welding tool 1700 shown in the first configuration. FIG. 21 is
a cross-sectional view of the welding tool 1700 shown in the first
configuration 1702. FIG. 22 is a cross-sectional view of the
welding tool 1700 shown in a second example configuration 2202.
FIG. 23 is a cross-sectional view of the welding tool 1700 shown in
a third example configuration 2302. FIG. 24 is a cross-sectional
view of the welding tool 1700 shown in a fourth example
configuration 2402.
[0122] The welding tool 1700 of FIGS. 17-24 includes an example
housing 1704, an example stabilization foot 1706, a first example
rod 1708, a second example rod 1710, a first example spring 1712, a
second example spring 1714, a first example hand grip 1716, a
second example hand grip 1718, an example cap 1720, a first example
air pressure conduit 1722, a second example air pressure conduit
1724, an example compaction foot 1726, a third example spring 1728,
an example ultrasonic exciter 1730, an example welder 1902, and an
example air cylinder 2002.
[0123] The housing 1704 of the welding tool 1700 is configured to
house, receive, contain, and/or carry one or more portion(s) of the
first rod 1708, the second rod 1710, the first hand grip 1716, the
second hand grip 1718, the cap 1720, the first air pressure conduit
1722, the second air pressure conduit 1724, the compaction foot
1726, the ultrasonic exciter 1730, the welder 1902, and/or the air
cylinder 2002 of the welding tool 1700. In the illustrated example
of FIGS. 17-24, the housing 1704 includes an example central
portion 1732. The central portion 1732 of the housing 1704 includes
an example upper (e.g., top) end 1734, an example lower (e.g.,
bottom) end 1736 located opposite the upper end 1734, an example
sidewall 1738 extending between the upper end 1734 and the lower
end 1736, and an example central axis 1740. The upper end 1734 of
the central portion 1732 is oriented away from the stabilization
foot 1706, and the lower end 1736 of the central portion 1732 is
oriented toward the stabilization foot 1706. In the illustrated
example of FIGS. 17-24, the sidewall 1738 of the central portion
1732 has a circular cross-sectional shape and/or area. In other
examples, the sidewall 1738 of the central portion 1732 can have a
different cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0124] Referring to FIG. 20, which is a cutaway view showing
interior structure of the welding tool 1700, the central portion
1732 of the housing 1704 can be seen to include an example opening
2004 defined by the sidewall 1738. The opening 2004 of the central
portion 1732 extends from the upper end 1734 of the central portion
1732 through to the lower end 1736 of the central portion 1732 in a
direction parallel to and coaxially aligned with the central axis
1740. The opening 2004 of the central portion 1732 is configured to
receive one or more portion(s) of the cap 1720, the compaction foot
1726, the ultrasonic exciter 1730, the welder 1902, and/or the air
cylinder 2002 of the welding tool 1700, such that the received
portion(s) of the cap 1720, the compaction foot 1726, the
ultrasonic exciter 1730, the welder 1902, and/or the air cylinder
2002 is/are circumscribed and/or otherwise bounded by the sidewall
1738 of the central portion 1732 of the housing 1704, as further
described below. In the illustrated example of FIGS. 17-24, the
opening 2004 of the central portion 1732 has a circular
cross-sectional shape and/or area. In other examples, the opening
2004 of the central portion 1732 can have a different
cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0125] As can be seen in FIG. 20, the central portion 1732 of the
housing 1704 further includes an example inwardly-extending flange
2006 located at and/or proximate to the lower end 1736 of the
central portion 1732 and extending inwardly from the sidewall 1738.
In the illustrated example of FIGS. 17-24, the inwardly-extending
flange 2006 of the central portion 1732 has a circular
cross-sectional shape and/or area. In other examples, the
inwardly-extending flange 2006 of the central portion 1732 can have
a different cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0126] In addition to the central portion 1732 described above, the
housing 1704 further includes a first example arm 1742 coupled to
and extending laterally (e.g., radially) away from the central
portion 1732 in a first direction, and a second example arm 1744
coupled to and extending laterally (e.g., radially) away from the
central portion 1732 in a second direction that is generally
opposite the first direction. Thus, the first arm 1742 and the
second arm 1744 are generally located on opposite sides of the
central portion 1732 of the housing 1704. In the illustrated
example of FIGS. 17-24, the first arm 1742 and the second arm 1744
are integrally formed with the central portion 1732 of the housing
1704. In other examples, the first arm 1742 and/or the second arm
1744 can alternatively be coupled (e.g., rigidly and/or fixedly
coupled) to the central portion 1732 of the housing 1704 via one or
more mechanical fastener(s).
[0127] The first arm 1742 of the housing 1704 includes an example
upper (e.g., top) end 1746, an example lower (e.g., bottom) end
1748 located opposite the upper end 1746, and an example sidewall
1750 extending between the upper end 1746 and the lower end 1748.
The upper end 1746 of the first arm 1742 is oriented away from the
stabilization foot 1706, and the lower end 1748 of the first arm
1742 is oriented toward the stabilization foot 1706. In the
illustrated example of FIGS. 17-24, the sidewall 1750 of the first
arm 1742 has a circular cross-sectional shape and/or area. In other
examples, the sidewall 1750 of the first arm 1742 can have a
different cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0128] Referring to FIG. 21, which shows a cross-sectional view of
the welding tool 1700, the first arm 1742 of the housing 1704 can
be seen to include an example opening 2102 defined by the sidewall
1750. The opening 2102 of the first arm 1742 extends from the upper
end 1746 of the first arm 1742 through to the lower end 1748 of the
first arm 1742 in a direction parallel to and laterally (e.g.,
radially) offset from the central axis 1740 of the central portion
1732 of the housing 1704. The opening 2102 of the first arm 1742 is
configured to receive a portion of the first rod 1708 of the
welding tool 1700 such that the received portion of the first rod
1708 is circumscribed and/or otherwise bounded by the sidewall 1750
of the first arm 1742 of the housing 1704. The opening 2102 of the
first arm 1742 slidably receives the first rod 1708 such that the
first arm 1742 and/or, more generally, the housing 1074 is slidable
along the first rod 1708 relative to (e.g., toward and/or away
from) the stabilization foot 1706. In the illustrated example of
FIGS. 17-24, the opening 2102 of the first arm 1742 has a circular
cross-sectional shape and/or area. In other examples, the opening
2102 of the first arm 1742 can have a different cross-sectional
shape and/or area (e.g., a non-circular cross-sectional shape
and/or area, a differently sized cross-sectional shape and/or area,
etc.).
[0129] The second arm 1744 of the housing 1704 similarly includes
an example upper (e.g., top) end 1752, an example lower (e.g.,
bottom) end 1754 located opposite the upper end 1752, and an
example sidewall 1756 extending between the upper end 1752 and the
lower end 1754. The upper end 1752 of the second arm 1744 is
oriented away from the stabilization foot 1076, and the lower end
1754 of the second arm 1744 is oriented toward the stabilization
foot 1706. In the illustrated example of FIGS. 17-24, the sidewall
1756 of the second arm 1744 has a circular cross-sectional shape
and/or area. In other examples, the sidewall 1756 of the second arm
1744 can have a different cross-sectional shape and/or area (e.g.,
a non-circular cross-sectional shape and/or area, a differently
sized cross-sectional shape and/or area, etc.).
[0130] Referring to FIG. 21, the second arm 1744 of the housing
1704 can be seen to similarly include an example opening 2104
defined by the sidewall 1756. The opening 2104 of the second arm
1744 extends from the upper end 1752 of the second arm 1744 through
to the lower end 1754 of the second arm 1744 in a direction
parallel to and laterally (e.g. radially) offset from the central
axis 1740 of the central portion 1732 of the housing 1704. The
opening 2104 of the second arm 1744 is configured to receive a
portion of the second rod 1710 of the welding tool 1700 such that
the received portion of the second rod 1710 is circumscribed and/or
otherwise bounded by the sidewall 1756 of the second arm 1744 of
the housing 1704. The opening 2104 of the second arm 1744 slidably
receives the second rod 1710 such that the second arm 1744 and/or,
more generally, the housing 1704 is slidable along the second rod
1710 relative to (e.g., toward and/or away from) the stabilization
foot 1706. In the illustrated example of FIGS. 17-24, the opening
2104 of the second arm 1744 has a circular cross-sectional shape
and/or area. In other examples, the opening 2104 of the second arm
1744 can have a different cross-sectional shape and/or area (e.g.,
a non-circular cross-sectional shape and/or area, a differently
sized cross-sectional shape and/or area, etc.).
[0131] As discussed above, the first and second arms 1742, 1744 of
the housing 1704 are integrally formed with the central portion
1732 of the housing 1704. The central portion 1732, the first arm
1742, and the second arm 1744 of the housing 1704 are accordingly
movable (e.g., slidable) in unison relative to (e.g., toward and/or
away from) the stabilization foot 1706. Movement of the housing
1704 (e.g., including the central portion 1732 and the first and
second arms 1742, 1744) toward the stabilization foot 1706 is
manually performed and/or manually controlled by a user (e.g., a
human operator) of the welding tool 1700, and is facilitated via
the first hand grip 1716 and/or the second hand grip 1718 of the
welding tool 1700. In the illustrated example of FIGS. 17-24, the
first hand grip 1716 is coupled to and extends away from the first
arm 1742 and/or the central portion 1732 of the housing 1704 in a
first direction, and the second hand grip 1718 is coupled to and
extends away from the second arm 1744 and/or the central portion
1732 of the housing 1704 in a second direction that is generally
opposite the first direction. Thus, the first hand grip 1716 and
the second hand grip 1718 are generally located on opposite sides
of the central portion 1732 of the housing 1704. The first hand
grip 1716 and the second hand grip 1718 are ergonomically
configured (e.g., ergonomically, sized, shaped, oriented, and/or
arranged) to be efficiently and/or comfortably gripped, grasped,
and/or held by the hands of an average adult-sized user of the
welding tool 1700. In the illustrated example of FIGS. 17-24, the
first hand grip 1716 and the second hand grip 1718 each have an
ellipsoidal and/or bulb-like shape. In other examples, the first
hand grip 1716 and/or the second hand grip 1718 can have a
different shape (e.g., a non-ellipsoidal and/or non-bulb-like
shape).
[0132] The stabilization foot 1706 of the welding tool 1700 is
configured to engage and/or stabilize one or more thermoplastic
part(s) of a thermoplastic composite layup prior to, during, and/or
following a compaction operation to be performed using the welding
tool 1700, and/or prior to, during, and/or following a welding
operation to be performed using the welding tool 1700. In the
illustrated example of FIGS. 17-24, the stabilization foot 1706
includes an example base 1758. The base 1758 of the stabilization
foot 1706 includes an example upper surface 1760, an example lower
(e.g., bottom) surface 1762 located opposite the upper surface
1760, an example peripheral edge 1764 extending between the upper
surface 1760 and the lower surface 1762, and an example central
axis 1766. The upper surface 1760 of the base 1758 is oriented
toward the central portion 1732 of the housing 1704, and the lower
surface 1762 of the base 1758 is oriented away from the central
portion 1732 of the housing 1704. Referring also to FIG. 19, which
shows a bottom view of welding tool 1700, the lower surface 1762 of
the base 1758 can be seen to form an example stabilization surface
1904 that is configured to engage and/or stabilize one or more
thermoplastic part(s) of a thermoplastic composite layup. In the
illustrated example of FIGS. 17-24, the stabilization surface 1904
of the base 1758 is substantially flat and/or planar. In other
examples, the stabilization surface 1904 of the base 1758 can
alternatively be curved (e.g., non-planar), contoured, or otherwise
shaped to support and/or complement an associated geometry of one
or more thermoplastic part(s) of a thermoplastic composite layup.
The central axis 1766 of the base 1758 of the stabilization foot
1706 is parallel to and coaxially aligned with the central axis
1740 of the central portion 1732 of the housing 1704. In the
illustrated example of FIGS. 17-24, the peripheral edge 1764 and
the stabilization surface 1904 of the base 1758 each have a
circular cross-sectional shape and/or area. In other examples, the
peripheral edge 1764 and/or the stabilization surface 1904 of the
base 1758 can have a different cross-sectional shape and/or area
(e.g., a non-circular cross-sectional shape and/or area, a
differently sized cross-sectional shape and/or area, etc.).
[0133] As can be seen in FIG. 19, the base 1758 of the
stabilization foot 1706 further includes an example central opening
1906, a first example offset opening 1908, and a second example
offset opening 1910. The central opening 1906 of the base 1758
extends from the upper surface 1760 of the base 1758 through to the
lower surface 1762 of the base 1758 in a direction parallel to and
coaxially aligned with central axis 1766. In the illustrated
example of FIGS. 17-24, the central opening 1906 of the base 1758
of the stabilization foot 1706 is parallel to and coaxially aligned
with the opening 2004 of the central portion 1732 of the housing
1704. The central opening 1906 of the base 1758 is configured to
receive (e.g., slidably receive) one or more portion(s) of the
compaction foot 1726 and/or the welder 1902 such that the received
portion(s) of the compaction foot 1726 and/or the welder 1902
is/are circumscribed and/or otherwise bounded by the base 1758 of
the stabilization foot 1706, as further described below. In the
illustrated example of FIGS. 17-24, the central opening 1906 of the
base 1758 has a circular cross-sectional shape and/or area. In
other examples, the central opening 1906 of the base 1758 can have
a different cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0134] The first offset opening 1908 of the base 1758 extends from
the upper surface 1760 of the base 1758 through to the lower
surface 1762 of the base 1758 in a direction parallel to and
laterally (e.g., radially) offset from the central axis 1766. In
the illustrated example of FIGS. 17-24, the first offset opening
1908 of the base 1758 of the stabilization foot 1706 is parallel to
and coaxially aligned with the opening 2102 of the first arm 1742
of the housing 1704. The first offset opening 1908 of the base 1758
is configured to receive a portion of the first rod 1708 of the
welding tool 1700 such that the received portion of the first rod
1708 is circumscribed and/or otherwise bounded by the base 1758 of
the stabilization foot 1706, as further described below. In the
illustrated example of FIGS. 17-24, the first offset opening 1908
of the base 1758 has a circular cross-sectional shape and/or area.
In other examples, the first offset opening 1908 of the base 1758
can have a different cross-sectional shape and/or area (e.g., a
non-circular cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0135] The second offset opening 1910 of the base 1758 extends from
the upper surface 1760 of the base 1758 through to the lower
surface 1762 of the base 1758 in a direction parallel to and
laterally (e.g., radially) offset from the central axis 1766. In
the illustrated example of FIGS. 17-24, the second offset opening
1910 of the base 1758 of the stabilization foot 1706 is parallel to
and coaxially aligned with the opening 2104 of the second arm 1744
of the housing 1704. The second offset opening 1910 of the base
1758 is configured to receive a portion of the second rod 1710 of
the welding tool 1700 such that the received portion of the second
rod 1710 is circumscribed and/or otherwise bounded by the base 1758
of the stabilization foot 1706, as further described below. In the
illustrated example of FIGS. 17-24, the second offset opening 1910
of the base 1758 has a circular cross-sectional shape and/or area.
In other examples, the second offset opening 1910 of the base 1758
can have a different cross-sectional shape and/or area (e.g., a
non-circular cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0136] While the base 1758 of the stabilization foot 1706 shown in
FIGS. 17-24 includes the central opening 1906, the first offset
opening 1908, and the second offset opening 1910 as described
above, in other examples the first offset opening 1908 and/or the
second offset opening 1910 can be omitted from the base 1758 of the
stabilization foot 1706. For example, the base 1758 of the
stabilization foot 1706 can alternatively include the central
opening 1906, and can omit the first and second offset openings
1908, 1910.
[0137] In addition to the base 1758 described above, the
stabilization foot 1706 further includes a first example leg 1768
and a second example leg 1770 respectively coupled to and extending
upward from the base 1758. The second leg 1770 is located above the
first offset opening 1908 of the base 1758 of the stabilization
foot 1706, and the second leg 1770 is located above the second
offset opening 1910 of the base 1758 of the stabilization foot
1706. In the illustrated example of FIGS. 17-24, the first leg 1768
and the second leg 1770 are integrally formed with the base 1758 of
the stabilization foot 1706. In other examples, the first leg 1768
and/or the second leg 1770 can alternatively be coupled (e.g.,
rigidly and/or fixedly coupled) to the base 1758 of the
stabilization foot 1706 via one or more mechanical fastener(s).
[0138] The first leg 1768 of the stabilization foot 1706 includes
an example upper (e.g., top) end 1772, an example lower (e.g.,
bottom) end 1774 located opposite the upper end 1772, and an
example sidewall 1776 extending between the upper end 1772 and the
lower end 1774.
[0139] The upper end 1772 of the first leg 1768 is oriented toward
the first arm 1742 of the housing 1704, and the lower end 1774 of
the first leg 1768 is oriented away from the first arm 1742 of the
housing 1704. In the illustrated example of FIGS. 17-24, the
sidewall 1776 of the first leg 1768 has a circular cross-sectional
shape and/or area. In other examples, the sidewall 1776 of the
first leg 1768 can have a different cross-sectional shape and/or
area (e.g., a non-circular cross-sectional shape and/or area, a
differently sized cross-sectional shape and/or area, etc.).
[0140] Referring to FIG. 21, the first leg 1768 of the
stabilization foot 1706 can be seen to include an example opening
2106 defined by the sidewall 1776. The opening 2106 of the first
leg 1768 extends from the upper end 1772 of the first leg 1768
through to the lower end 1774 of the first leg 1768 in a direction
parallel to and laterally (e.g. radially) offset from the central
axis 1766 of the base 1758 of the stabilization foot 1706. In the
illustrated example of FIGS. 17-24, the opening 2106 of the first
leg 1768 of the stabilization foot 1706 is parallel to and
coaxially aligned with the opening 2102 of the first arm 1742 of
the housing 1704, and/or parallel to and coaxially aligned with the
first offset opening 1908 of the base 1758 of the stabilization
foot 1706. The opening 2106 of the first leg 1768 is configured to
receive a portion of the first rod 1708 of the welding tool 1700
such that the received portion of the first rod 1708 is
circumscribed and/or otherwise bounded by the sidewall 1776 of the
first leg 1768 of the stabilization foot 1706. The opening 2106 of
the first leg 1768 receives the first rod 1708 such that the first
rod 1708 is rigidly, fixedly, and/or non-movably coupled (e.g., via
a threaded engagement, an adhesive, etc.) to the first leg 1768
and/or, more generally, to the stabilization foot 1706. In the
illustrated example of FIGS. 17-24, the opening 2106 of the first
leg 1768 has a circular cross-sectional shape and/or area. In other
examples, the opening 2106 of the first leg 1768 can have a
different cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0141] The second leg 1770 of the stabilization foot 1706 includes
an example upper (e.g., top) end 1778, an example lower (e.g.,
bottom) end 1780 located opposite the upper end 1778, and an
example sidewall 1782 extending between the upper end 1778 and the
lower end 1780. The upper end 1778 of the second leg 1770 is
oriented toward the second arm 1744 of the housing 1704, and the
lower end 1780 of the second leg 1770 is oriented away from the
second arm 1744 of the housing 1704. In the illustrated example of
FIGS. 17-24, the sidewall 1782 of the second leg 1770 has a
circular cross-sectional shape and/or area. In other examples, the
sidewall 1782 of the second leg 1770 can have a different
cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0142] Referring to FIG. 21, the second leg 1770 of the
stabilization foot 1706 can be seen to include an example opening
2108 defined by the sidewall 1782. The opening 2108 of the second
leg 1770 extends from the upper end 1778 of the second leg 1770
through to the lower end 1780 of the second leg 1770 in a direction
parallel to and laterally (e.g. radially) offset from the central
axis 1766 of the base 1758 of the stabilization foot 1706. In the
illustrated example of FIGS. 17-24, the opening 2108 of the second
leg 1770 of the stabilization foot 1706 is parallel to and
coaxially aligned with the opening 2104 of the second arm 1744 of
the housing 1704, and/or parallel to and coaxially aligned with the
second offset opening 1910 of the base 1758 of the stabilization
foot 1706. The opening 2108 of the second leg 1770 is configured to
receive a portion of the second rod 1710 of the welding tool 1700
such that the received portion of the second rod 1710 is
circumscribed and/or otherwise bounded by the sidewall 1782 of the
second leg 1770 of the stabilization foot 1706. The opening 2108 of
the second leg 1770 receives the second rod 1710 such that the
second rod 1710 is rigidly, fixedly, and/or non-movably coupled
(e.g., via a threaded engagement, an adhesive, etc.) to the second
leg 1770 and/or, more generally, to the stabilization foot 1706. In
the illustrated example of FIGS. 17-24, the opening 2108 of the
second leg 1770 has a circular cross-sectional shape and/or area.
In other examples, the opening 2108 of the second leg 1770 can have
a different cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0143] The first rod 1708 of the welding tool 1700 is configured to
guide movement of the housing 1704 of the welding tool 1700
relative to (e.g., toward or away from) the stabilization foot 1706
of the welding tool 1700. In the illustrated example of FIGS.
17-24, the first rod 1708 includes an example upper (e.g., top) end
1784, and, as can be seen in FIG. 19, an example lower (e.g.,
bottom) end 1912 located opposite the upper end 1784. A portion of
the first rod 1708 proximate the upper end 1784 of the first rod
1708 is located and/or positioned within the opening 2102 of the
first arm 1742 of the housing 1704 such that the first arm 1742 of
the housing 1704 is slidably coupled to the first rod 1708. In some
examples, a portion of the first rod 1708 located proximate the
upper end 1784 of the first rod 1708 can include a mechanical stop
(e.g., an outwardly-extending flange) configured to prevent the
first arm 1742 of the housing 1704 from sliding upwardly past
and/or off of the upper end 1784 of the first rod 1708. A portion
of the first rod 1708 proximate the lower end 1912 of the first rod
1708 is located and/or positioned within the opening 2106 of the
first leg 1768 of the stabilization foot 1706 and/or within the
first offset opening 1908 of the base 1758 of the stabilization
foot 1706 such that the first rod 1708 is rigidly and/or fixedly
coupled to the first leg 1768 and/or the base 1758 of the
stabilization foot 1706. In some examples, a portion of the first
rod 1708 proximate the lower end 1912 of the first rod 1708 can
include threads configured to mate with a threaded portion of the
opening 2106 of the first leg 1768 of the stabilization foot 1706
and/or with a threaded portion of the first offset opening 1908 of
the base 1758 of the stabilization foot 1706 to rigidly and/or
fixedly couple the first rod 1708 to the first leg 1768 and/or the
base 1758 of the stabilization foot 1706. In the illustrated
example of FIGS. 17-24, the first rod 1708 has a circular
cross-sectional shape and/or area. In other examples, the first rod
1708 can have a different cross-sectional shape and/or area (e.g.,
a non-circular cross-sectional shape and/or area, a differently
sized cross-sectional shape and/or area, etc.).
[0144] The second rod 1710 of the welding tool 1700 is configured
to guide movement of the housing 1704 of the welding tool 1700
relative to (e.g., toward or away from) the stabilization foot 1706
of the welding tool 1700. In the illustrated example of FIGS.
17-24, the second rod 1710 includes an example upper (e.g., top)
end 1786, and, as can be seen in FIG. 19, an example lower (e.g.,
bottom) end 1914 located opposite the upper end 1786. A portion of
the second rod 1710 proximate the upper end 1786 of the second rod
1710 is located and/or positioned within the opening 2104 of the
second arm 1744 of the housing 1704 such that the second arm 1744
of the housing 1704 is slidably coupled to the second rod 1710. In
some examples, a portion of the second rod 1710 located proximate
the upper end 1786 of the second rod 1710 can include a mechanical
stop (e.g., an outwardly-extending flange) configured to prevent
the second arm 1744 of the housing 1704 from sliding upwardly past
and/or off of the upper end 1786 of the second rod 1710. A portion
of the second rod 1710 proximate the lower end 1914 of the second
rod 1710 is located and/or positioned within the opening 2108 of
the second leg 1770 of the stabilization foot 1706 and/or within
the second offset opening 1910 of the base 1758 of the
stabilization foot 1706 such that the second rod 1710 is rigidly
and/or fixedly coupled to the second leg 1770 and/or the base 1758
of the stabilization foot 1706. In some examples, a portion of the
second rod 1710 proximate the lower end 1914 of the second rod 1710
can include threads configured to mate with a threaded portion of
the opening 2108 of the second leg 1770 of the stabilization foot
1706 and/or with a threaded portion of the second offset opening
1910 of the base 1758 of the stabilization foot 1706 to rigidly
and/or fixedly couple the second rod 1710 to the second leg 1770
and/or the base 1758 of the stabilization foot 1706. In the
illustrated example of FIGS. 17-24, the second rod 1710 has a
circular cross-sectional shape and/or area. In other examples, the
second rod 1710 can have a different cross-sectional shape and/or
area (e.g., a non-circular cross-sectional shape and/or area, a
differently sized cross-sectional shape and/or area, etc.).
[0145] The first spring 1712 of the welding tool 1700 is configured
to bias the housing 1704 of the welding tool 1700 away from the
stabilization foot 1706 of the welding tool 1700. In the
illustrated example of FIGS. 17-24, the first spring 1712
circumscribes (e.g., is coiled about and/or around) the first rod
1708, and is located and/or positioned on the first rod 1708
between the first arm 1742 of the housing 1704 and the first leg
1768 of the stabilization foot 1706. The first spring 1712 includes
an example upper (e.g., top) end 1788 in contact with the lower end
1748 of the first arm 1742 of the housing 1704, and an example
lower (e.g., bottom) end 1790 located opposite the upper end 1788
and in contact with the upper end 1772 of the first leg 1768 of the
stabilization foot 1706. The first spring 1712 biases the first arm
1742 of the housing 1704 away from the first leg 1768 of the
stabilization foot 1706 and/or, more generally, biases the housing
1704 of the welding tool 1700 away from the stabilization foot 1706
of the welding tool 1700. In the illustrated example of FIGS.
17-24, the first spring 1712 is compressible in response to a
downward force of sufficient magnitude (e.g., a magnitude greater
than that of a spring force associated with the first spring 1712)
applied to the first arm 1742 of the housing 1704 (e.g., by a human
operator of the welding tool 1700 via the first hand grip 1716).
Compression of the first spring 1712 by such an applied downward
force enables the first arm 1742 of the housing 1704 to move and/or
slide toward the first leg 1768 of the stabilization foot 1706
and/or, more generally, enables the housing 1704 to move and/or
slide toward the stabilization foot 1706.
[0146] The second spring 1714 of the welding tool 1700 is
configured to bias the housing 1704 of the welding tool 1700 away
from the stabilization foot 1706 of the welding tool 1700. In the
illustrated example of FIGS. 17-24, the second spring 1714
circumscribes (e.g., is coiled about and/or around) the second rod
1710, and is located and/or positioned on the second rod 1710
between the second arm 1744 of the housing 1704 and the second leg
1770 of the stabilization foot 1706. The second spring 1714
includes an example upper (e.g., top) end 1792 in contact with the
lower end 1754 of the second arm 1744 of the housing 1704, and an
example lower (e.g., bottom) end 1794 located opposite the upper
end 1792 and in contact with the upper end 1778 of the second leg
1770 of the stabilization foot 1706. The second spring 1714 biases
the second arm 1744 of the housing 1704 away from the second leg
1770 of the stabilization foot 1706 and/or, more generally, biases
the housing 1704 of the welding tool 1700 away from the
stabilization foot 1706 of the welding tool 1700. In the
illustrated example of FIGS. 17-24, the second spring 1714 is
compressible in response to a downward force of sufficient
magnitude (e.g., a magnitude greater than that of a spring force
associated with the second spring 1714) applied to the second arm
1744 of the housing 1704 (e.g., by a human operator of the welding
tool 1700 via the second hand grip 1718). Compression of the second
spring 1714 by such an applied downward force enables the second
arm 1744 of the housing 1704 to move and/or slide toward the second
leg 1770 of the stabilization foot 1706 and/or, more generally,
enables the housing 1704 to move and/or slide toward the
stabilization foot 1706.
[0147] The cap 1720 of the welding tool 1700 is located and/or
positioned within the opening 2004 of the central portion 1732 of
the housing 1704, and is configured to close off the upper end of
the opening 2004. As can be seen in FIG. 20, the cap 1720 includes
an example upper (e.g., top) end 2008, an example lower (e.g.,
bottom) end 2010 located opposite the upper end 2008, and an
example sidewall 2012 extending between the upper end 2008 and the
lower end 2010. The upper end 2008 of the cap 1720 is oriented
toward the upper end 1734 of the central portion 1732 of the
housing 1704, and the lower end 2010 of the cap 1720 is oriented
toward the lower end 1736 of the central portion 1732 of the
housing 1704. In some examples, the sidewall 2012 of the cap 1720
can include threads configured to mate with a threaded portion of
the opening 2004 of the central portion 1732 of the housing 1704 to
rigidly and/or fixedly couple the cap 1720 to the central portion
1732 of the housing 1704. In the illustrated example of FIGS.
17-24, the sidewall 2012 of the cap 1720 has a circular
cross-sectional shape and/or area. In other examples, the sidewall
2012 of the cap 1720 can have a different cross-sectional shape
and/or area (e.g., a non-circular cross-sectional shape and/or
area, a differently sized cross-sectional shape and/or area,
etc.).
[0148] Referring to FIG. 21, the cap 1720 can be seen to include an
example opening 2110. The opening 2110 of the cap 1720 extends from
the upper end 2008 of the cap 1720 through to the lower end 2010 of
the cap 1720 in a direction parallel to and coaxially aligned with
central axis 1740 of the central portion 1732 of the housing 1704.
The opening 2110 of the cap 1720 is configured to receive a portion
of the ultrasonic exciter 1730 of the welding tool 1700 such that
the received portion of the ultrasonic exciter 1730 is
circumscribed and/or otherwise bounded by the cap 1720, as further
described below. In some examples, the opening 2110 of the cap
1720, and/or the portion of the ultrasonic exciter 1730 received
therein, is/are fitted with or carry one or more O-rings configured
to create an air-tight seal between the opening 2110 of the cap
1720 and the portion of the ultrasonic exciter 1730 received
therein. In the illustrated example of FIGS. 17-24, the opening
2110 of the cap 1720 has a circular cross-sectional shape and/or
area. In other examples, the opening 2110 of the cap 1720 can have
a different cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0149] The first air pressure conduit 1722 and the second air
pressure conduit 1724 of the welding tool 1700 respectively carry
pressurized air that is selectively and/or controllably supplied to
the first air pressure conduit 1722 and/or the second air pressure
conduit 1724 to control movement and/or the position of the air
cylinder 2002 and/or the welder 1902. In the illustrated example of
FIGS. 17-24, the first air pressure conduit 1722 extends through
the cap 1720 into the opening 2004 of the central portion 1732 of
the housing 1704, and the second air pressure conduit 1724 extends
through the sidewall 1378 of the central portion 1732 of the
housing 1704 into the opening 2004 of the central portion 1732 of
the housing 1704. As further described below, the first air
pressure conduit 1722 extends into an upper region of the opening
2004 located and/or positioned above a head of the air cylinder
2002, and the second air pressure conduit 1724 extends into a lower
region of the opening 2004 located and/or positioned below the head
of the air cylinder 2002. Pressurized air supplied via the first
air pressure conduit 1722 causes the air cylinder 2002 and/or the
welder 1902 to move toward the stabilization foot 1706. Pressurized
air supplied via the second air pressure conduit 1724 causes the
air cylinder 2002 and/or the welder 1902 to move away from the
stabilization foot 1706.
[0150] The compaction foot 1726 of the welding tool 1700 is
configured to engage, compact, and/or debulk one or more
thermoplastic part(s) of a thermoplastic composite layup prior to,
during and/or following a welding operation to be performed using
the welding tool 1700. As can be seen in FIG. 20, the compaction
foot 1726 includes an example upper (e.g., top) end 2014, an
example lower (e.g., bottom) end 2016 located opposite the upper
end 2014, an example sidewall 2018 extending between the upper end
2014 and the lower end 2016, and an example central axis 2020. The
upper end 2014 of the compaction foot 1726 is oriented away from
the stabilization foot 1706, and the lower end 2016 of the
compaction foot 1726 is oriented toward the stabilization foot
1706. The central axis 2020 of the compaction foot 1726 is parallel
to and coaxially aligned with the central axis 1740 of the central
portion 1732 of the housing 1704, and/or parallel to and coaxially
aligned with the central axis 1766 of the base 1758 of the
stabilization foot 1706. In the illustrated example of FIGS. 17-24,
the sidewall 2018 of the compaction foot 1726 has a circular
cross-sectional shape and/or area. In other examples, the sidewall
2018 of the compaction foot 1726 can have a different
cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0151] In some examples, the sidewall 2018 of the compaction foot
1726 contacts and/or engages an O-ring carried by the
inwardly-extending flange 2006 of the central portion 1732 of the
housing 1704, with the O-ring creating an air-tight seal between
the sidewall 2018 of the compaction foot 1726 and the
inwardly-extending flange 2006 of the central portion 1732 of the
housing 1704. In some examples, the sidewall 2018 of the compaction
foot 1726 carries an O-ring that contacts and/or engages a neck of
the air cylinder 2002, with the O-ring creating an air-tight seal
between the sidewall 2018 of the compaction foot 1726 and the neck
of the air cylinder 2002.
[0152] As can be seen in FIG. 20, the compaction foot 1726 further
includes an example opening 2022 defined by the sidewall 2018. The
opening 2022 of the compaction foot 1726 extends from the upper end
2014 of the compaction foot 1726 through to the lower end 2016 of
the compaction foot 1726 in a direction parallel to and coaxially
aligned with the central axis 2020. The opening 2022 of the
compaction foot 1726 is configured to receive one or more
portion(s) of the welder 1902 and/or the air cylinder 2002, such
that the received portion(s) of the welder 1902 and/or the air
cylinder 2002 is/are circumscribed and/or otherwise bounded by the
sidewall 2018 of the compaction foot 1726, as further described
below. In the illustrated example of FIGS. 17-24, the opening 2022
of the compaction foot 1726 has a circular cross-sectional shape
and/or area. In other examples, the opening 2022 of the compaction
foot 1726 can have a different cross-sectional shape and/or area
(e.g., a non-circular cross-sectional shape and/or area, a
differently sized cross-sectional shape and/or area, etc.).
[0153] As can be seen in FIG. 20, the compaction foot 1726 further
includes a first example outwardly-extending flange 2024 located at
and/or proximate to the upper end 2014 of the compaction foot 1726
and extending outwardly from the sidewall 2018 of the compaction
foot 1726, a second example outwardly-extending flange 2026 located
between the upper end 2014 and the lower end 2016 of the compaction
foot 1726 and extending outwardly from the sidewall 2018 of the
compaction foot 1726, and an example inwardly-extending flange 2028
located at and/or proximate to the lower end 2016 of the compaction
foot 1726 and extending inwardly from the sidewall 2018 of the
compaction foot 1726.
[0154] The first outwardly-extending flange 2024 of the compaction
foot 1726 is located within the opening 2004 of the central portion
1732 of the housing 1704. The first outwardly-extending flange 2024
of the compaction foot 1726 provides a downward mechanical stop
that is engageable with the inwardly-extending flange 2006 of the
sidewall 1738 of the central portion 1732 of the housing 1704 to
prevent the compaction foot 1726 from moving downward (e.g., toward
and/or past the stabilization foot 1706) beyond a configured
distance. In some examples, the first outwardly-extending flange
2024 of the compaction foot 1726 can be removably coupled (e.g.,
via a threaded connection) to the sidewall 2018 of the compaction
foot 1726 to facilitate positioning and/or securing the compaction
foot 1726 within the central portion 1732 of the housing 1704
during assembly of the welding tool 1700. In the illustrated
example of FIGS. 17-24, the first outwardly-extending flange 2024
of the compaction foot 1726 has a circular cross-sectional shape
and/or area. In other examples, the first outwardly-extending
flange 2024 of the compaction foot 1726 can have a different
cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0155] The second outwardly-extending flange 2026 of the compaction
foot 1726 is located and/or positioned between the
inwardly-extending flange 2006 of the sidewall 1738 of the central
portion 1732 of the housing 1704 and the upper surface 1760 of the
base 1758 of the stabilization foot 1706. The second
outwardly-extending flange 2026 of the compaction foot 1726
supports the third spring 1728 of the welding tool 1700, as further
described below. In the illustrated example of FIGS. 17-28, the
second outwardly-extending flange 2026 of the compaction foot 1726
has a circular cross-sectional shape and/or area. In other
examples, the second outwardly-extending flange 2026 of the
compaction foot 1726 can have a different cross-sectional shape
and/or area (e.g., a non-circular cross-sectional shape and/or
area, a differently sized cross-sectional shape and/or area,
etc.).
[0156] As can be seen in FIG. 19, the inwardly-extending flange
2028 of the compaction foot 1726 forms an example compaction
surface 1916 that is configured to engage, compact and/or debulk
one or more thermoplastic part(s) of a thermoplastic composite
layup. In the illustrated example of FIGS. 17-24, the compaction
surface 1916 of the compaction foot 1726 is substantially flat
and/or planar. In other examples, the compaction surface 1916 of
the compaction foot 1726 can alternatively be curved (e.g.,
non-planar), contoured, or otherwise shaped to support and/or
complement an associated geometry of one or more thermoplastic
part(s) of a thermoplastic composite layup. In the illustrated
example of FIGS. 17-24, the inwardly-extending flange 2028 and the
compaction surface 1916 of the compaction foot 1726 each have a
circular cross-sectional shape and/or area. In other examples, the
inwardly-extending flange 2028 and/or the compaction surface 1916
of the compaction foot 1726 can have a different cross-sectional
shape and/or area (e.g., a non-circular cross-sectional shape
and/or area, a differently sized cross-sectional shape and/or area,
etc.).
[0157] The third spring 1728 of the welding tool 1700 is configured
to bias the compaction foot 1726 of the welding tool 1700 away from
the housing 1704 of the welding tool 1700. In the illustrated
example of FIGS. 17-24, the third spring 1728 circumscribes (e.g.,
is coiled about and/or around) the sidewall 2018 of the compaction
foot 1726, and is located and/or positioned on the compaction foot
1726 between the inwardly-extending flange 2006 of the central
portion 1732 of the housing 1704 and the second outwardly-extending
flange 2026 of the compaction foot 1726. As can be seen in FIG. 20,
the third spring 1728 includes an example upper (e.g., top) end
2030 in contact with the inwardly-extending flange 2006 of the
central portion 1732 of the housing 1704, and an example lower
(e.g., bottom) end 2032 located opposite the upper end 2030 and in
contact with the second outwardly-extending flange 2026 of the
compaction foot 1726. The third spring 1728 biases the second
outwardly-extending flange 2026 of the compaction foot 1726 of the
welding tool 1700 away from the inwardly-extending flange 2006 of
the central portion 1732 of the housing 1704 and/or, more
generally, biases the compaction foot 1726 of the welding tool 1700
away from the housing 1704 of the welding tool 1700. In the
illustrated example of FIGS. 17-24, the third spring 1728 is
compressible in response to a downward force of sufficient
magnitude (e.g., a magnitude greater than that of a spring force
associated with the third spring 1728) applied to the housing 1704
(e.g., by a human operator of the welding tool 1700 via the first
hand grip 1716 and/or the second hand grip 1718). Compression of
the third spring 1728 by such an applied downward force enables the
second outwardly-extending flange 2026 of the compaction foot 1726
to move and/or slide toward the inwardly-extending flange 2006 of
the central portion 1732 of the housing 1704 and/or, more
generally, enables the compaction foot 1726 to move and/or slide
toward the housing 1704.
[0158] The air cylinder 2002 of the welding tool 1700 is configured
to move the welder 1902 of the welding tool 1700 relative to the
housing 1704 of the welding tool 1700, relative to the
stabilization foot 1706 of the welding tool 1700, and/or relative
to the compaction foot 1726 of the welding tool 1700, with any
and/or all such movements being in conjunction with a welding
operation and/or process to be performed using the welding tool
1700. As can be seen in FIG. 20, the air cylinder 2002 includes an
example upper (e.g., top) end 2034, an example lower (e.g., bottom)
end 2036 located opposite the upper end 2034, an example sidewall
2038 extending between the upper end 2034 and the lower end 2036,
and an example central axis 2040. The upper end 2034 of the air
cylinder 2002 is oriented away from the stabilization foot 1706,
and the lower end 2036 of the air cylinder 2002 is oriented toward
the stabilization foot 1706. The central axis 2040 of the air
cylinder 2002 is parallel to and coaxially aligned with the central
axis 1740 of the central portion 1732 of the housing 1704, parallel
to and coaxially aligned with the central axis 1766 of the base
1758 of the stabilization foot 1706, and/or parallel to and
coaxially aligned with the central axis 2020 of the compaction foot
1726. In the illustrated example of FIGS. 17-24, the sidewall 2038
of the air cylinder 2002 has a circular cross-sectional shape
and/or area. In other examples, the sidewall 2038 of the air
cylinder 2002 can have a different cross-sectional shape and/or
area (e.g., a non-circular cross-sectional shape and/or area, a
differently sized cross-sectional shape and/or area, etc.).
[0159] Referring to FIG. 21, the air cylinder 2002 can be seen to
include an example opening 2112 defined by the sidewall 2038. The
opening 2112 of the air cylinder 2002 extends from the upper end
2034 of the air cylinder 2002 through to the lower end 2036 of the
air cylinder 2002 in a direction parallel to and coaxially aligned
with the central axis 2040. The opening 2112 of the air cylinder
2002 is configured to receive one or more portion(s) of the welder
1902 and/or the ultrasonic exciter 1730, such that the received
portion(s) of the welder 1902 and/or the ultrasonic exciter 1730
is/are circumscribed and/or otherwise bounded by the sidewall 2038
of the air cylinder 2002, as further described below. In the
illustrated example of FIGS. 17-24, the opening 2112 of the air
cylinder 2002 has a circular cross-sectional shape and/or area. In
other examples, the opening 2112 of the air cylinder 2002 can have
a different cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0160] As can be seen in FIG. 20, the air cylinder 2002 further
includes an example head 2042 located at and/or proximate to the
upper end 2034 of the air cylinder 2002. The head 2042 of the air
cylinder 2002 is located within the opening 2004 of the central
portion 1732 of the housing 1704, and/or between the cap 1720 of
the welding tool 1700 and the inwardly-extending flange 2006 of the
central portion 1732 of the housing 1704 of the welding tool 1700.
As can be seen in FIG. 20, the head 2042 of the air cylinder 2002
carries one or more example O-ring(s) 2044 that individually and/or
collectively create an air-tight seal between the head 2042 of the
air cylinder 2002 and the sidewall 1738 of the central portion 1732
of the housing 1704. In this regard, the head 2042 and the
O-ring(s) 2044 is/are located and/or positioned between the first
air pressure conduit 1722 and the second air pressure conduit 1724
of the welding tool 1700. Pressurized air supplied via the first
air pressure conduit 1722 enters an upper region of the opening
2004 of the central portion 1732 of the housing 1704 located and/or
positioned above the head 2042 and/or above the O-ring(s) 2044 of
the air cylinder 2002, and causes the air cylinder 2002 to move
toward the stabilization foot 1706. Pressurized air supplied via
the second air pressure conduit 1724 enters a lower region of the
opening 2004 of the central portion 1732 of the housing 1704
located and/or positioned below the head 2042 and/or below the
O-ring(s) 2044 of the air cylinder 2002, and causes the air
cylinder 2002 to move away from the stabilization foot 1706. In the
illustrated example of FIGS. 17-24, the head 2042 of the air
cylinder 2002 has a circular cross-sectional shape and/or area. In
other examples, the head 2042 of the air cylinder 2002 can have a
different cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0161] As can be seen in FIG. 20, the air cylinder 2002 further
includes an example neck 2046 located at and/or proximate to the
lower end 2036 of the air cylinder 2002. The neck 2046 of the air
cylinder 2002 is configured to be slidably received within the
opening 2022 of the compaction foot 1726 such that the air cylinder
2002 is movable relative to the stabilization foot 1706
independently from the compaction foot 1726 moving relative to the
stabilization foot 1706, and vice-versa. In the illustrated example
of FIGS. 17-24, the neck 2046 of the air cylinder 2002 has a
circular cross-sectional shape and/or area. In other examples, the
neck 2046 of the air cylinder 2002 can have a different
cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0162] The welder 1902 of the welding tool 1700 is configured to
weld (e.g., tack weld) a thermoplastic part to one or more other
thermoplastic part(s) of a thermoplastic composite layup in
conjunction with a welding operation to be performed using the
welding tool 1700, during a compaction operation to be performed
using the welding tool 1700, and/or during a stabilization
operation to be performed using the welding tool 1700. The welder
1902 can be implemented as an ultrasonic welder that is powered,
controlled and/or operated by the ultrasonic exciter 1730 and/or by
a power supply operatively coupled to the ultrasonic exciter 1730.
In some examples, a power supply configured to power the ultrasonic
exciter 1730 and/or the welder 1902 can be mounted on the welding
tool 1700. In other examples, the power supply can alternatively be
located remotely from the welding tool 1700. In some examples, the
power supply is adjustable such that the ultrasonic exciter 1730
and/or the welder 1902 can operate at different (e.g., adjustable)
power settings depending upon material and/or specification
requirements associated with the welding operation to be
performed.
[0163] As can be seen in FIG. 20, the welder 1902 includes an
example horn 2048, an example welding tip 2050, and an example
central axis 2052. The central axis 2052 of the welder 1902 is
parallel to and coaxially aligned with the central axis 1740 of the
central portion 1732 of the housing 1704, parallel to and coaxially
aligned with the central axis 1766 of the base 1758 of the
stabilization foot 1706, parallel to and coaxially aligned with the
central axis 2020 of the compaction foot 1726, and/or parallel to
and coaxially aligned with the central axis 2040 of the air
cylinder 2002. In the illustrated example of FIGS. 17-24, the
welder 1902 has a circular cross-sectional shape and/or area. In
other examples, the welder 1902 can have a different
cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0164] The horn 2048 of the welder 1902 is located and/or
positioned within the opening 2112 and/or the neck 2046 of the air
cylinder 2002 such that the horn 2048 and/or, more generally, the
welder 1902 is rigidly and/or fixedly coupled to the air cylinder
2002. In some examples, the horn 2048 can include threads
configured to mate with a threaded portion of the opening 2112 of
the air cylinder 2002 to rigidly and/or fixedly couple the horn
2048 and/or, more generally, the welder 1902 to the air cylinder
2002. In other examples, the horn 2048 can additionally or
alternatively include threads configured to mate with a threaded
portion of the ultrasonic exciter 1730 to rigidly and/or fixedly
couple the horn 2048 and/or, more generally, the welder 1902 to the
ultrasonic exciter 1730. In the illustrated example of FIGS. 17-24,
the horn 2048 has a circular cross-sectional shape and/or area. In
other examples, the horn 2048 can have a different cross-sectional
shape and/or area (e.g., a non-circular cross-sectional shape
and/or area, a differently sized cross-sectional shape and/or area,
etc.).
[0165] As can be seen in FIG. 19, the welding tip 2050 of the
welder 1902 forms an example welding surface 1918 that is
configured to weld a thermoplastic part to one or more other
thermoplastic part(s) of a thermoplastic composite layup. In the
illustrated example of FIGS. 17-24, the welding surface 1918 of the
welding tip 2050 is substantially flat and/or planar. In other
examples, the welding surface 1918 of the welding tip 2050 can
alternatively be curved (e.g., non-planar), contoured, or otherwise
shaped. In the illustrated example of FIGS. 17-24, the welding tip
2050 and the welding surface 1918 each have a circular
cross-sectional shape and/or area. In other examples, the welding
tip 2050 and/or the welding surface 1918 can have a different
cross-sectional shape and/or area (e.g., a non-circular
cross-sectional shape and/or area, a differently sized
cross-sectional shape and/or area, etc.).
[0166] The ultrasonic exciter 1730 of the welding tool 1700 is
configured to generate ultrasonic signals (e.g., via a generator
and a transducer of the ultrasonic exciter 1730), and to
mechanically transfer the generated ultrasonic signals to the horn
2048 of the welder 1902. Referring to FIG. 21, the ultrasonic
exciter 1730 can be seen to include a first example portion 2114
located and/or positioned within the opening 2110 of the cap 1720,
and a second example portion 2116 located and/or positioned within
the opening 2112 of the air cylinder 2002. The ultrasonic exciter
1730 is movable along the central axis 1740 of the central portion
1732 of the housing 1704 in unison with movement of the air
cylinder 2002 and/or movement of the welder 1902. In the
illustrated example of FIGS. 17-24, the ultrasonic exciter 1730 has
a circular cross-sectional shape and/or area. In other examples,
the ultrasonic exciter 1730 can have a different cross-sectional
shape and/or area (e.g., a non-circular cross-sectional shape
and/or area, a differently sized cross-sectional shape and/or area,
etc.).
[0167] In the illustrated example of FIGS. 17-24, the welding
surface 1918 of the welder 1902, the compaction surface 1916 of the
compaction foot 1726, and the stabilization surface 1904 of the
stabilization foot 1706 are concentrically located and/or
positioned relative to one another, with the compaction surface
1916 circumscribing the welding surface 1918, and the stabilization
surface 1904 circumscribing the compaction surface 1916. When the
welding tool 1700 is placed on a first thermoplastic part of a
thermoplastic composite layup, the stabilization surface 1904 is
configured to provide and/or impart a first pressure and/or a first
force to the first thermoplastic part, over an area consistent with
the geometry of the stabilization surface 1904, to stabilize the
first thermoplastic part relative to one or more other
thermoplastic part(s) of the thermoplastic composite layup. The
compaction surface 1916 in turn is configured to provide and/or
impart a second pressure and/or a second force to the first
thermoplastic part, over an area consistent with the geometry of
the compaction surface 1916, to compact and/or debulk the first
thermoplastic part and/or one or more other thermoplastic part(s)
of the thermoplastic composite layup. The welding surface 1918 in
turn is configured to provide and/or impart a third pressure and/or
a third force to the first thermoplastic part, over an area
consistent with the geometry of the welding surface 1918, to weld
(e.g., tack weld) the first thermoplastic part to one or more other
thermoplastic part(s) of the thermoplastic composite layup.
[0168] The housing 1704 of the welding tool 1700 is movable along
the central axis 1740 between a neutral (e.g., uncompressed)
position of the housing 1704 and a compressed position of the
housing 1704. Movement of the housing 1704 occurs relative to the
stabilization foot 1706. For example, the housing 1704 can be
moved, along the central axis 1740, from an example neutral
position of the housing 1704 (e.g., a position in which the housing
1704 is separated from the stabilization foot 1706 by a first
distance) associated with the first configuration 1702 of the
welding tool 1700 shown in FIGS. 17-21 to an example compressed
position of the housing 1704 (e.g., a position in which the housing
1704 is separated from the stabilization foot 1706 by a second
distance less than the first distance associated with the neutral
position of the housing 1704) associated with the second
configuration 2202 of the welding tool 1700 shown in FIG. 22, the
third configuration 2302 of the welding tool 1700 shown in FIG. 23,
and/or the fourth configuration 2402 of the welding tool 1700 shown
in FIG. 24. The first spring 1712 and/or the second spring 1714 of
the welding tool 1700 has/have a first length when the housing 1704
is in the neutral position, and a second length less than the first
length when the housing 1704 is in the compressed position.
[0169] The housing 1704 can be moved along the central axis 1740
from and/or into a variety of different compressed positions. In
other words, the housing 1704 can have variable and/or adjustable
compressed positions. For example, the compressed position of the
housing 1704 can vary based on the extent and/or degree of force
that may be required of the stabilization surface 1904 and/or the
stabilization foot 1706 to stabilize a first thermoplastic part
relative to one or more other thermoplastic part(s) of a
thermoplastic composite layup. In some examples, the stabilization
surface 1904 of the stabilization foot 1706 can stabilize a first
thermoplastic part relative to a second thermoplastic part while
the compaction surface 1916 of the compaction foot 1726 compacts
and/or debulks the first thermoplastic part, and/or while the
welding surface 1918 of the welder 1902 welds the first
thermoplastic part to the second thermoplastic part. In such
examples, once the stabilization operation is complete, the housing
1704 can retract back from the compressed position of the housing
1704 associated with the second configuration 2202 of the welding
tool 1700 shown in FIG. 22, the third configuration 2302 of the
welding tool 1700 shown in FIG. 23, and/or the fourth configuration
2402 of the welding tool 1700 shown in FIG. 24, to the neutral
position of the housing 1704 associated with the first
configuration 1702 of the welding tool 1700 shown in FIGS.
17-24.
[0170] In the illustrated example of FIGS. 17-24, the
above-described movements of the housing 1704 occur and/or are
performed manually by a human operator of the welding tool 1700,
with the housing 1704 being forced toward the stabilization foot
1706 in response to the human operator gripping and/or grasping the
first hand grip 1716 and/or the second hand grip 1718 of the
welding tool 1700 and applying a downward force thereto. In this
regard, movement of the housing 1704 toward the stabilization foot
1706 occurs when the operator-applied downward force is
sufficiently powerful to overcome the spring force(s) generated by
the first spring 1712 and/or the second spring 1714 of the welding
tool 1700 that bias the housing 1704 away from the stabilization
foot 1706. When the stabilization surface 1904 of the stabilization
foot 1706 is placed in contact with a thermoplastic part of a
thermoplastic composite layup, an increase to the operator-applied
downward force produces a corresponding and/or associated increase
to the force by which the stabilization surface 1904 of the
stabilization foot 1706 stabilizes the thermoplastic part.
[0171] The compaction foot 1726 of the welding tool 1700 is movable
(e.g., independent of movement of the welder 1902) along the
central axis 2020 between a neutral (e.g. uncompressed) position of
the compaction foot 1726 and a compressed position of the
compaction foot 1726. In some examples, movement of the compaction
foot 1726 occurs relative to the housing 1704, relative to the
stabilization foot 1706, and/or relative to the welder 1902. For
example, the compaction surface 1916 and/or, more generally, the
compaction foot 1726 can be moved, along the central axis 2020,
from an example neutral position of the compaction foot 1726 (e.g.,
a position in which the second outwardly-extending flange 2026 of
the compaction foot 1726 is separated from the inwardly-extending
flange 2006 of the central portion 1732 of the housing 1704 by a
third distance) associated with the first configuration 1702 of the
welding tool 1700 shown in FIGS. 17-21, and/or the second
configuration 2202 of the welding tool 1700 shown in FIG. 22, to an
example compressed position of the compaction foot 1726 (e.g., a
position in which the second outwardly-extending flange 2026 of the
compaction foot 1726 is separated from the inwardly-extending
flange 2006 of the central portion 1732 of the housing 1704 by a
fourth distance less than the third distance associated with the
neutral position of the compaction foot 1726) associated with the
third configuration 2302 of the welding tool 1700 shown in FIG. 23,
and/or the fourth configuration 2402 of the welding tool 1700 shown
in FIG. 24.
[0172] The compaction surface 1916 and/or, more generally, the
compaction foot 1726 can be moved along the central axis 2020 from
and/or into a variety of different compressed positions. In other
words, the compaction surface 1916 and/or the compaction foot 1726
can have variable and/or adjustable compressed positions. For
example, the compressed position of the compaction surface 1916
and/or the compaction foot 1726 can vary based on the extent and/or
degree of compaction that may be required of the compaction surface
1916 and/or the compaction foot 1726 to compact and/or debulk a
first thermoplastic part relative to one or more other
thermoplastic part(s) of a thermoplastic composite layup. In some
examples, the compaction surface 1916 of the compaction foot 1726
can compact and/or debulk a first thermoplastic part relative to a
second thermoplastic part while the stabilization surface 1904 of
the stabilization foot 1706 stabilizes the first thermoplastic
part, and/or while the welding surface 1918 of the welder 1902
welds the first thermoplastic part to the second thermoplastic
part. In such examples, once the compaction operation is complete,
the compaction surface 1916 of the compaction foot 1726 can retract
back from the compressed position of the compaction foot 1726
associated with the third configuration 2302 of the welding tool
1700 shown in FIG. 23, and/or the fourth configuration 2402 of the
welding tool 1700 shown in FIG. 24, to the neutral (e.g.,
uncompressed) position of the compaction foot 1726 associated with
the first configuration 1702 of the welding tool 1700 shown in
FIGS. 17-21, and/or the second configuration 2202 of the welding
tool 1700 shown in FIG. 22.
[0173] In the illustrated example of FIGS. 17-24, the
above-described movements of the compaction surface 1916 and/or,
more generally, the compaction foot 1726 occur and/or are performed
manually by a human operator of the welding tool 1700, with the
compaction foot 1726 being forced toward the housing 1704 in
response to the human operator gripping and/or grasping the first
hand grip 1716 and/or the second hand grip 1718 of the welding tool
1700 and applying a downward force thereto. In this regard,
movement of the compaction foot 1726 toward the housing 1704 occurs
when the operator-applied downward force is sufficiently powerful
to overcome the spring force generated by the third spring 1728 of
the welding tool 1700 that bias the compaction foot 1726 away from
the housing 1704. When the stabilization surface 1904 of the
stabilization foot 1706 is already stabilizing a thermoplastic part
of a thermoplastic composite layup, an increase to the
operator-applied downward force produces a corresponding and/or
associated increase to the force by which the compaction surface
1916 of the compaction foot 1726 compacts and/or debulks the
thermoplastic part relative to one or more other thermoplastic
part(s) of the thermoplastic composite layup.
[0174] The welder 1902 of the welding tool 1700 is movable (e.g.,
independent of movement of the compaction foot 1726) along the
central axis 2052 between a retracted position of the welder 1902
and an extended position of the welder 1902. In some examples,
movement of the welder 1902 occurs relative to the housing 1704,
relative to the stabilization foot 1706, and/or relative of the
compaction foot 1726. For example, the welding surface 1918 and/or,
more generally, the welder 1902 can be moved, along the central
axis 2052, from an example retracted position of the welder 1902
(e.g., a position in which the welding surface 1918 of the welder
1902 is located above the stabilization surface 1904 of the
stabilization foot 1706, and/or above the compaction surface 1916
of the compaction foot 1726) associated with the first
configuration 1702 of the welding tool 1700 shown in FIGS. 17-21,
the second configuration 2202 of the welding tool 1700 shown in
FIG. 22, and/or the third configuration 2302 of the welding tool
1700 shown in FIG. 23, to an example extended position of the
welder 1902 (e.g., a position in which the welding surface 1918 of
the welder 1902 is flush with or located below the stabilization
surface 1904 of the stabilization foot 1706, and/or flush with or
located below the compaction surface 1916 of the compaction foot
1726) associated with the fourth configuration 2402 of the welding
tool 1700 shown in FIG. 24.
[0175] The welding surface 1918 and/or, more generally, the welder
1902 can be moved along the central axis 2052 from and/or into a
variety of different extended positions. In other words, the
welding surface 1918 and/or the welder 1902 can have variable
and/or adjustable extended positions. For example, the extended
position of the welding surface 1918 and/or the welder 1902 can
vary based on the extent and/or degree of extension that may be
required of the welding surface 1918 and/or the welder 1902 to weld
(e.g., tack weld) a first thermoplastic part to one or more other
thermoplastic part(s) of a thermoplastic composite layup. In some
examples, the welding surface 1918 of the welder 1902 can weld a
first thermoplastic part to a second thermoplastic part while the
stabilization surface 1904 of the stabilization foot 1706
stabilizes the first thermoplastic part, and/or while the
compaction surface 1916 of the compaction foot 31726 compacts the
first thermoplastic part. In such examples, once the welding
operation is complete, the welding surface 1918 of the welder 1902
can retract back from the extended position of the welder 1902
associated with the fourth configuration 2402 of the welding tool
1700 shown in FIG. 24 to the retracted position of the welder 1902
associated with the first configuration 1702 of the welding tool
1700 shown in FIGS. 17-21, the second configuration 2202 of the
welding tool 1700 shown in FIG. 22, and/or the third configuration
2302 of the welding tool 1700 shown in FIG. 23.
[0176] In the illustrated example of FIGS. 17-24, the
above-described movements of the welding surface 1918 and/or, more
generally, the welder 1902 occur and/or are performed in an
automated manner, with the welder 1902 being driven and/or
controlled by pressurized air delivered in a regulated manner to
the air cylinder 2002 through the first air pressure conduit 1722
and/or the second air pressure conduit 1724. The pressure and/or
the force at which the welder 1902 operates (e.g., the pressure
and/or the force at which the welder 1902 welds a first
thermoplastic part to a second thermoplastic part) can accordingly
be controlled and/or adjusted via the regulated supply of
pressurized air delivered to the air cylinder 2002. The period of
time (e.g., the duration) for which the welding surface 1918
and/or, more generally, the welder 1902 remains in any particular
position (e.g., any retracted position or any extended position)
can also be controlled and/or adjusted via the regulated supply of
pressurized air to the air cylinder 2002. In some examples, the
pressure and/or the force at which the welder 1902 operates, and/or
the period of time for which the welding surface 1918 and/or, more
generally, the welder 1902 remains in any particular position can
be automatically determined and/or implemented based on material
and/or specification requirements associated with the welding
operation to be performed. In some examples, the automated delivery
and/or regulated supply of pressurized air to the air cylinder 2002
can be initiated in response to a human operator of the welding
tool 1700 actuating a user input device (e.g., a button, a switch,
a foot pedal, etc.) that is operatively coupled to the welding tool
1700 and/or operatively coupled to the supply source of the
pressurized air. In other examples, the automated delivery and/or
regulated supply of pressurized air to the air cylinder 2002 can
alternatively be initiated in response to a human operator of the
welding tool 1700 maintaining the housing 1704 in a compressed
position for a predetermined time period, and/or in response to a
human operator of the welding tool 1700 maintaining the compaction
foot 1726 in a compressed position for a predetermined time
period.
[0177] When the welding tool 1700 of FIGS. 17-24 is in the first
configuration 1702 shown in FIGS. 17-21, the housing 1704 is in a
neutral (e.g., uncompressed) position, the compaction foot 1726 is
in a neutral (e.g., uncompressed) position, and the welder 1902 is
in a retracted position. More specifically, when the welding tool
1700 is in the first configuration 1702 shown in FIGS. 17-21, the
lower end 1736 of the central portion 1732 of the housing 1704 is
spaced apart from the upper surface 1760 of the base 1758 of the
stabilization foot 1706 by a first distance, the compaction surface
1916 of the compaction foot 1726 is located and/or positioned above
the stabilization surface 1904 of the stabilization foot 1706, and
the welding surface 1918 of the welder 1902 is located and/or
positioned above the stabilization surface 1904 of the
stabilization foot 1706 and/or above the compaction surface 1916 of
the compaction foot 1726.
[0178] When the welding tool 1700 of FIGS. 17-24 is in the second
configuration 2202 shown in FIG. 22, the housing 1704 is in a
compressed position, the compaction foot 1726 is in a neutral
(e.g., uncompressed) position, and the welder 1902 is in a
retracted position. More specifically, when the welding tool 1700
is in the second configuration 2202 shown in FIG. 22, the lower end
1736 of the central portion 1732 of the housing 1704 is spaced
apart from the upper surface 1760 of the base 1758 of the
stabilization foot 1706 by a second distance that is less than the
first distance described above in connection with the first
configuration 1702 of FIGS. 17-21. When the welding tool 1700 is in
the second configuration 2202 shown in FIG. 22, the compaction
surface 1916 of the compaction foot 1726 is flush with or below
(e.g., slightly below) the stabilization surface 1904 of the
stabilization foot 1706, and the second outwardly-extending flange
2026 of the compaction foot 1726 is spaced apart from the
inwardly-extending flange 2006 of the central portion 1732 of the
housing 1704 by a third distance. When the welding tool 1700 is in
the second configuration 2202 shown in FIG. 22, the welding surface
1918 of the welder 1902 is located and/or positioned above the
stabilization surface 1904 of the stabilization foot 1706 and/or
above the compaction surface 1916 of the compaction foot 1726.
[0179] When the welding tool 1700 of FIGS. 17-24 is in the third
configuration 2302 shown in FIG. 23, the housing 1704 is in a
compressed position, the compaction foot 1726 is in a compressed
position, and the welder 1902 is in a retracted position. More
specifically, when the welding tool 1700 is in the third
configuration 2302 shown in FIG. 23, the lower end 1736 of the
central portion 1732 of the housing 104 is spaced apart from the
upper surface 1760 of the base 1758 of the stabilization foot 1706
by a fourth distance that is that is less than the second distance
described above in connection with the second configuration 2202 of
FIG. 22. When the welding tool 1700 is in the third configuration
2302 shown in FIG. 23, the compaction surface 1916 of the
compaction foot 1726 is flush with or below (e.g., slightly below)
the stabilization surface 1904 of the stabilization foot 1706, and
the second outwardly-extending flange 2026 of the compaction foot
1726 is spaced apart from the inwardly-extending flange 2006 of the
central portion 1732 of the housing 1704 by a fifth distance that
is less than the third distance described above in connection with
the second configuration 2202 of FIG. 22. When the welding tool
1700 is in the third configuration 2302 shown in FIG. 23, the
welding surface 1918 of the welder 1902 is located and/or
positioned above the stabilization surface 1904 of the
stabilization foot 1706 and/or above the compaction surface 1916 of
the compaction foot 1726.
[0180] When the welding tool 1700 of FIGS. 17-24 is in the fourth
configuration 2402 shown in FIG. 24, the housing 1704 is in a
compressed position, the compaction foot 1726 is in a compressed
position, and the welder 1902 is in an extended position. More
specifically, when the welding tool 1700 is in the fourth
configuration 2402 shown in FIG. 24, the lower end 1736 of the
central portion 1732 of the housing 1704 is spaced apart from the
upper surface 1760 of the base 1758 of the stabilization foot 1706
by the fourth distance described above in connection with the third
configuration 2302 of FIG. 23. When the welding tool 1700 is in the
fourth configuration 2402 shown in FIG. 24, the compaction surface
1916 of the compaction foot 1726 is flush with or below (e.g.,
slightly below) the stabilization surface 1904 of the stabilization
foot 1706, and the second outwardly-extending flange 2026 of the
compaction foot 1726 is spaced apart from the inwardly-extending
flange 2006 of the central portion 1732 of the housing 1704 by the
fifth distance described above in connection with the third
configuration 2302 of FIG. 23. When the welding tool 1700 is in the
fourth configuration 2402 shown in FIG. 24, the welding surface
1918 of the welder 1902 is located and/or positioned flush with or
below (e.g., slightly below) the stabilization surface 1904 of the
stabilization foot 1706, and/or flush with or below (e.g., slightly
below) the compaction surface 1916 of the compaction foot 1726.
[0181] FIGS. 25-31 illustrate example stages (e.g., a first example
stage 2502, a second example stage 2602, a third example stage
2702, a fourth example stage 2802, a fifth example stage 2902, a
sixth example stage 3002, and a seventh example stage 3102) of an
example process 2500 to be implemented via the welding tool 1700 of
FIGS. 17-24 to weld a first example thermoplastic part 2504 to a
second example thermoplastic part 2506. As further described below,
the process 2500 includes stabilizing the first thermoplastic part
2504 relative to the second thermoplastic part 2506, compacting
and/or debulking the stabilized first and second thermoplastic
parts 2504, 2506, and welding the compacted first and second
thermoplastic parts 2504, 2506 to one another in the course of
forming a thermoplastic composite layup including at least the
first thermoplastic part 2504 and the second thermoplastic part
2506.
[0182] The first and second thermoplastic parts 2504, 2506 of FIGS.
25-31 can respectively be of any size, shape, and/or configuration
(e.g., a substantially flat and/or planar shape, a tapered shape, a
sloped shape, a curved shape, a contoured shape, etc.). In some
examples, the first thermoplastic part, 2504, the second
thermoplastic part 2506, and/or one or more other thermoplastic
part(s) of an example thermoplastic composite layup 2508 including
the first thermoplastic part 2504, the second thermoplastic part
2506, and/or the one or more other thermoplastic part(s) can
include one or more ply drop(s) and/or one or more area(s) of
significant bulk. In some examples, the first thermoplastic part
2504 and the second thermoplastic part 2506 are respectively
single-ply thermoplastic parts. In other examples, the first
thermoplastic part 2504 and/or the second thermoplastic part 2506
can alternatively be a multi-ply thermoplastic part, with the
multiple plies of the multi-ply thermoplastic part(s) either being
welded together or not yet welded together. In some examples, the
thermoplastic composite layup 2508 may be located and/or positioned
on an example layup table 2510 while the process 2500 of FIGS.
25-31 is being performed.
[0183] FIG. 25 illustrates the first stage 2502 of the example
process 2500. During the first stage 2502, the welding tool 1700 is
manually placed (e.g., by a human operator of the welding tool
1700) onto the first thermoplastic part 2504 such that the
stabilization surface 1904 of the stabilization foot 1706 contacts
at least a portion of the first thermoplastic part 2504. The
welding tool 1700 is positioned and/or remains positioned in the
first configuration 1702 of FIGS. 17-21 described above while the
first stage 2502 is being performed.
[0184] FIG. 26 illustrates the second stage 2602 of the example
process 2500. During the second stage 2602, the housing 1704 is
manually moved (e.g., by a human operator of the welding tool 1700)
toward the stabilization foot 1706 such that the stabilization
surface 1904 of the stabilization foot 1706 stabilizes the first
thermoplastic part 2504 relative to the second thermoplastic part
2506. The housing 1704 is accordingly moved from a neutral (e.g.,
uncompressed) position to a first compressed position in connection
with the second stage 2602 of the process 2500. The welding tool
1700 transitions from being positioned in the first configuration
1702 of FIGS. 17-21 described above to being positioned in the
second configuration 2202 of FIG. 22 described above while the
second stage 2602 is being performed.
[0185] FIG. 27 illustrates the third stage 2702 of the example
process 2500. During the third stage 2702, the housing 1704 is
manually moved (e.g., by a human operator of the welding tool 1700)
further toward the stabilization surface 1904 of the stabilization
foot 1706 from its first compressed position to a second compressed
position. Also during the third stage 2702 of the process 2500 of
FIGS. 25-31, the compaction foot 1726 is manually moved (e.g., by a
human operator of the welding tool 1700) toward the housing 1704
from a neutral (e.g., uncompressed) position to a compressed
position in which the compaction surface 1916 of the compaction
foot 1726 compacts and/or debulks the first thermoplastic part 2504
and/or the second thermoplastic part 2506. The welding tool 1700
transitions from being positioned in the second configuration 2202
of FIG. 22 described above to being positioned in the third
configuration 2302 of FIG. 23 described above while the third stage
2702 is being performed.
[0186] FIG. 28 illustrates the fourth stage 2802 of the example
process 2500. During the fourth stage 2802, the welder 1902 is
automatically moved (e.g., by a controlled and/or regulated supply
of pressurized air delivered to the air cylinder 2002 via the first
air pressure conduit 1722 of the welding tool 1700) from a
retracted position to an extended position in which the welding
surface 1918 of the welder 1902 forms an example weld 2804 that
fixedly couples the first thermoplastic part 2504 to the second
thermoplastic part 2506. The welding tool 1700 transitions from
being positioned in the third configuration 2302 of FIG. 23
described above to being positioned in the fourth configuration
2402 of FIG. 24 described above while the fourth stage 2802 is
being performed.
[0187] FIG. 29 illustrates the fifth stage 2902 of the example
process 2500. During the fifth stage 2902, the welder 1902 is
automatically moved (e.g., by a controlled and/or regulated supply
of pressurized air delivered to the air cylinder 2002 via the
second air pressure conduit 1724 of the welding tool 1700) from its
extended position back to its retracted position subsequent to
(e.g., immediately following) the welder 1902 forming the weld
2804. The welding tool 1700 transitions from being positioned in
the fourth configuration 2402 of FIG. 24 described above to being
positioned in the third configuration 2302 of FIG. 23 described
above while the fifth stage 2902 is being performed.
[0188] FIG. 30 illustrates the sixth stage 3002 of the example
process 2500. During the sixth stage 3002, the housing 1704 is
moved (e.g., by a spring force associated with the first spring
1712 and/or the second spring 1714 of the welding tool 1700 in
response to the human operator of the welding tool 1700 reducing a
manually-applied force) away from the stabilization foot 1706, from
its second compressed position to its first compressed position.
Also during the sixth stage 3002 of the process 2500 of FIGS.
25-31, the compaction foot 1726 is moved (e.g., by a spring force
associated with the third spring 1728 of the welding tool 1700 in
response to the human operator of the welding tool 1700 reducing a
manually-applied force) away from the housing 1704, from its
compressed position to its neutral position. The welding tool 1700
transitions from being positioned in the third configuration 2302
of FIG. 23 described above to being positioned in the second
configuration 2202 of FIG. 22 described above while the sixth stage
3002 is being performed.
[0189] FIG. 31 illustrates the seventh stage 3102 of the example
process 2500. During the seventh stage 3102, the housing 1704 is
moved (e.g., by a spring force associated with the first spring
1712 and/or the second spring 1714 of the welding tool 1700 in
response to the human operator of the welding tool 1700 releasing a
manually-applied force) further away from the stabilization foot
1706, from its first compressed position to its neutral position.
The welding tool 1700 transitions from being positioned in the
second configuration 2202 of FIG. 22 described above to being
positioned in the first configuration 1702 of FIGS. 17-21 described
above while the seventh stage 3102 is being performed.
[0190] FIG. 32 is a flowchart representative of an example method
3200 for implementing the example welding tool 1700 of FIGS. 17-24
to weld a first example thermoplastic part to a second example
thermoplastic part. In some examples, the method 3200 can be
implemented in connection with the welding tool 1700 being utilized
to perform the example process 2500 of FIGS. 25-31 described above.
The method 3200 includes manually placing (e.g., by a human
operator) the welding tool 1700 onto a first thermoplastic part
(e.g., the first thermoplastic part 2504 of FIGS. 25-31) stacked
above a second thermoplastic part (e.g., the second thermoplastic
part 2506 of FIGS. 25-31) (block 3202). For example, the welding
tool 1700 can be placed on the first thermoplastic part such that
the stabilization surface 1904 of the stabilization foot 1706
contacts at least a portion of the first thermoplastic part. The
welding tool 1700 is positioned and/or remains positioned in the
first configuration 1702 of FIGS. 17-21 described above while block
3202 of the method 3200 is being performed. Following block 3202,
the method 3200 proceeds to block 3204.
[0191] At block 3204, the method 3200 includes manually moving
(e.g., by a human operator) the housing 1704 of the welding tool
1700 toward the stabilization foot 1706 of the welding tool 1700
(e.g., from a neutral position to a first compressed position) to
cause the stabilization surface 1904 of the stabilization foot 1706
to stabilize the first thermoplastic part relative to the second
thermoplastic part. The welding tool 1700 transitions from being
positioned in the first configuration 1702 of FIGS. 17-21 described
above to being positioned in the second configuration 2202 of FIG.
22 described above while block 3204 of the method 3200 is being
performed. Following block 3204, the method 3200 proceeds to block
3206.
[0192] At block 3206, the method 3200 includes manually moving
(e.g., by a human operator of the welding tool 1700) the housing
1704 of the welding tool 1700 further toward the stabilization
surface 1904 of the stabilization foot 1706 from its first
compressed position to a second compressed position, and further
includes manually moving (e.g., by a human operator of the welding
tool 1700) the compaction foot 1726 of the welding tool 1700 toward
the housing 1704 of the welding tool 1700 from a neutral (e.g.,
uncompressed) position to a compressed position in which the
compaction surface 1916 of the compaction foot 1726 compacts and/or
debulks the first thermoplastic part and/or the second
thermoplastic part. The welding tool 1700 transitions from being
positioned in the second configuration 2202 of FIG. 22 described
above to being positioned in the third configuration 2302 of FIG.
23 described above while block 3206 of the method 3200 is being
performed. Following block 3206, the method 3200 proceeds to block
3208.
[0193] At block 3208, the method 3200 includes automatically moving
(e.g., by a controlled and/or regulated supply of pressurized air
delivered to the air cylinder 2002 via the first air pressure
conduit 1722 of the welding tool 1700) the welder 1902 of the
welding tool 1700 from a retracted position to an extended position
to cause the welding surface 1918 of the welder 1902 to form a weld
(e.g., the weld 2804 of FIGS. 28-31) that fixedly couples the first
thermoplastic part to the second thermoplastic part. The welding
tool 1700 transitions from being positioned in the third
configuration 2302 of FIG. 23 described above to being positioned
in the fourth configuration 2402 of FIG. 24 described above while
block 3208 of the method 3200 is being performed. Following block
3208, the method 3200 proceeds to block 3210.
[0194] At block 3210, the method 3200 includes automatically moving
(e.g., by a controlled and/or regulated supply of pressurized air
delivered to the air cylinder 2002 via the second air pressure
conduit 1724 of the welding tool 1700) the welder 1902 of the
welding tool 1700 from its extended position back to its retracted
position subsequent to (e.g., immediately following) the welder
1902 of the welding tool 1700 forming the weld. The welding tool
1700 transitions from being positioned in the fourth configuration
2402 of FIG. 24 described above to being positioned in the third
configuration 2302 of FIG. 23 described above while block 3210 of
the method 3200 is being performed. Following block 3210, the
method 3200 proceeds to block 3212.
[0195] At block 3212, the method 3200 includes moving (e.g., by a
spring force associated with the first spring 1712 and/or the
second spring 1714 of the welding tool 1700 in response to the
human operator of the welding tool 1700 reducing a manually-applied
force) the housing 1704 of the welding tool 1700 away from the
stabilization foot 1706 of the welding tool 1700, from its second
compressed position to its first compressed position, and further
includes moving (e.g., by a spring force associated with the third
spring 1728 of the welding tool 1700 in response to the human
operator of the welding tool 1700 reducing a manually-applied
force) the compaction foot 1726 of the welding tool 1700 away from
the housing 1704 of the welding tool 1700, from its compressed
position to its neutral position. The welding tool 1700 transitions
from being positioned in the third configuration 2302 of FIG. 23
described above to being positioned in the second configuration
2202 of FIG. 22 described above while block 3212 of the method 3200
is being performed. Following block 3212, the method 3200 proceeds
to block 3214.
[0196] At block 3214, the method 3200 includes moving (e.g., by a
spring force associated with the first spring 1712 and/or the
second spring 1714 of the welding tool 1700 in response to the
human operator of the welding tool 1700 releasing a
manually-applied force) the housing 1704 of the welding tool 1700
further away from the stabilization foot 1706 of the welding tool
1700, from its first compressed position to its neutral position.
The welding tool 1700 transitions from being positioned in the
second configuration 2202 of FIG. 22 described above to being
positioned in the first configuration 1702 of FIGS. 17-21 described
above while block 3214 of the method 3200 is being performed.
Following block 3214, the method 3200 ends.
[0197] From the foregoing, it will be appreciated that example
methods and apparatus for semi-automated tack welding of plies of a
thermoplastic composite layup are disclosed. The disclosed methods
and apparatus include and/or utilize a welding tool having a
stabilization foot configured to stabilize a first thermoplastic
ply relative to a second thermoplastic ply, a compaction foot
configured to compact and/or debulk the first thermoplastic ply
relative to the second thermoplastic ply, and a welder configured
to tack weld the first thermoplastic ply to the second
thermoplastic ply in connection with forming a thermoplastic
composite layup. In some disclosed examples, the stabilization foot
of the welding tool configured to stabilize the first thermoplastic
ply relative to the second thermoplastic ply in response to a
housing of the welding tool being manually moved (e.g., by a human
operator of the welding tool) toward the stabilization foot. In
some disclosed examples, the stabilization foot of the welding tool
is configured to be manually operated and/or manually controlled by
a human operator of the welding tool, and the compaction foot and
the welder of the welding tool are configured to be automatically
operated and/or automatically controlled. In other disclosed
examples, the stabilization foot and the compaction foot of the
welding tool are configured to be manually operated and/or manually
controlled by a human operator of the welding tool, and the welder
of the welding tool is configured to be automatically operated
and/or automatically controlled.
[0198] The disclosed methods and apparatus provide numerous
advantages relative to conventional manual tack welding operations.
For example, the disclosed methods and apparatus advantageously
enable a human operator to stabilize and debulk one or more
thermoplastic plies of a thermoplastic composite layup in a
controlled manner as the plies are tack welded, and/or to apply the
correct amount of weld pressure, for the correct time period, to
facilitate tack welding the plies of the thermoplastic composite
layup. The disclosed method and apparatus accordingly reduce and/or
eliminate much or all of the subjectivity that is inherent in
conventional manual tack welding operations. Additionally, the
disclosed methods and apparatus advantageously cause the welding
tip of the welder of the welding tool to be shrouded (e.g., by the
compaction foot of the welding tool and/or by the stabilization
foot of the welding tool) while the tack weld is formed. The
disclosed method and apparatus accordingly provide a safety
advantage to a human operator of the welding tool relative to the
safety risks that the human operator may be inherently exposed to
in connection with conventional manual tack welding operations.
[0199] The following paragraphs provide various examples of the
examples disclosed herein.
[0200] Example 1 includes a welding tool. The welding tool of
Example 1 comprises a stabilization foot, a housing, a compaction
foot, and a welder. The stabilization foot has a stabilization
surface. The housing has a central axis. The housing is movable
relative to the stabilization surface along the central axis of the
housing. The compaction foot has a central axis and a compaction
surface. The compaction surface is movable relative to the
stabilization surface and to the housing along the central axis of
the compaction foot. The welder has a central axis and a welding
surface. The welding surface is movable relative to the
stabilization surface, to the housing, and to the compaction
surface along the central axis of the welder.
[0201] Example 2 includes the welding tool of Example 1, wherein
the central axis of the housing, the central axis of the compaction
foot, and the central axis of the welder are parallel.
[0202] Example 3 includes the welding tool of any of Examples 1-2,
wherein the central axis of the housing, the central axis of the
compaction foot, and the central axis of the welder are coaxially
aligned.
[0203] Example 4 includes the welding tool of any of Examples 1-3,
wherein the compaction surface circumscribes the welding surface,
and wherein the stabilization surface circumscribes the compaction
surface.
[0204] Example 5 includes the welding tool of any of Examples 1-4,
wherein the housing is movable along the central axis of the
housing between a neutral position and a compressed position, and
wherein the stabilization surface is configured to stabilize a
first thermoplastic part relative to a second thermoplastic part
when the housing is in the compressed position.
[0205] Example 6 includes the welding tool of Example 5, further
comprising a spring operatively positioned between the housing and
the stabilization foot, wherein the spring is configured to bias
the housing into the neutral position, and wherein the housing is
configured to be manually moved from the neutral position into the
compressed position against a spring force generated by the
spring.
[0206] Example 7 includes the welding tool of any of Examples 1-4,
wherein the compaction surface is movable along the central axis of
the compaction foot between a retracted position and an extended
position, and wherein the compaction surface is configured to
compact a first thermoplastic part relative to a second
thermoplastic part when the compaction foot is in the extended
position.
[0207] Example 8 includes the welding tool of Example 7, wherein
the compaction surface is configured to be automatically moved from
the retracted position to the extended position in response to
pressurized air delivered in a controlled manner to a portion of
the compaction foot located within the housing.
[0208] Example 9 includes the welding tool of any of Examples 7-8,
wherein the compaction surface is positioned above the
stabilization surface when the compaction surface is in the
retracted position, and wherein the compaction surface is
positioned flush with or below the stabilization surface when the
compaction surface is in the extended position.
[0209] Example 10 includes the welding tool of any of Examples 1-4,
wherein the compaction surface is movable along the central axis of
the compaction foot between a neutral position and a compressed
position, and wherein the compaction surface is configured to
compact a first thermoplastic part relative to a second
thermoplastic part when the compaction foot is in the compressed
position.
[0210] Example 11 includes the welding tool of Examples 10, further
comprising a spring operatively positioned between the compaction
foot and the housing, wherein the spring is configured to bias the
compaction foot into the neutral position, and wherein the
compaction foot is configured to be manually moved from the neutral
position into the compressed position against a spring force
generated by the spring.
[0211] Example 12 includes the welding tool of any of Examples
10-11, wherein the compaction surface is positioned flush with or
below the stabilization surface when the compaction surface is in
the compressed position.
[0212] Example 13 includes the welding tool of any of Examples 1-4,
wherein the welding surface is movable along the central axis of
the welder between a retracted position and an extended position,
and wherein the welding surface is configured to weld a first
thermoplastic part to a second thermoplastic part when the welding
surface is in the extended position.
[0213] Example 14 includes the welding tool of Example 13, wherein
the welding surface is configured to be automatically moved from
the retracted position to the extended position in response to
pressurized air delivered in a controlled manner to an air cylinder
located within the housing, wherein the air cylinder is movable
along the central axis of the welder, and wherein the welder is
fixedly coupled to the air cylinder.
[0214] Example 15 includes the welding tool of any of Examples
13-14, wherein the welding surface is positioned above the
stabilization surface when the welding surface is in the retracted
position, and wherein the welding surface is positioned flush with
or below the stabilization surface when the welding surface is in
the extended position.
[0215] Example 16 includes a method for welding a first
thermoplastic part to a second thermoplastic part via a welding
tool. The method of Example 16 comprises positioning a
stabilization surface of a stabilization foot of the welding tool
in contact with the first thermoplastic part. The method of Example
16 further comprises stabilizing the first thermoplastic part
relative to the second thermoplastic part by moving a housing of
the welding tool toward the stabilization surface along a central
axis of the housing. The method of Example 16 further comprises
compacting the first thermoplastic part relative to the second
thermoplastic part by moving a compaction surface of a compaction
foot of the welding tool into contact with the first thermoplastic
part and relative to the stabilization foot and to the housing
along a central axis of the compaction foot. The method of Example
16 further comprises welding the first thermoplastic part to the
second thermoplastic part by moving a welding surface of a welder
of the welding tool into contact with the first thermoplastic part
and relative to the stabilization surface, to the housing, and to
the compaction surface along a central axis of the welder.
[0216] Example 17 includes the method of Examples 16, wherein the
central axis of the housing, the central axis of the compaction
foot, and the central axis of the welder are parallel.
[0217] Example 18 includes the method of any of Examples 16-17,
wherein the central axis of the housing, the central axis of the
compaction foot, and the central axis of the welder are coaxially
aligned.
[0218] Example 19 includes the method of any of Examples 16-18,
wherein stabilizing the first thermoplastic part relative to the
second thermoplastic part includes moving the housing along the
central axis of the housing from a neutral position to a compressed
position.
[0219] Example 20 includes the method of Example 19, wherein moving
the housing from the neutral position to the compressed position
includes manually moving the housing from the neutral position into
the compressed position against a spring force generated by a
spring of the welding tool, wherein the spring is operatively
positioned between the housing and the stabilization foot, and
wherein the spring biases the housing into the neutral
position.
[0220] Example 21 includes the method of any of Examples 16-18,
wherein compacting the first thermoplastic part relative to the
second thermoplastic part includes moving the compaction surface
along the central axis of the compaction foot from a retracted
position to an extended position.
[0221] Example 22 includes the method of Examples 21, wherein
moving the compaction surface from the retracted position to the
extended position includes automatically moving the compaction
surface from the retracted position into the extended position by
delivering pressurized air in a controlled manner to a portion of
the compaction foot located within the housing.
[0222] Example 23 includes the method of any of Examples 21-22,
wherein the compaction surface is positioned above the
stabilization surface when the compaction surface is in the
retracted position, and wherein the compaction surface is
positioned flush with or below the stabilization surface when the
compaction surface is in the extended position.
[0223] Example 24 includes the method of any of Examples 16-18,
wherein compacting the first thermoplastic part relative to the
second thermoplastic part includes moving the compaction surface
along the central axis of the compaction foot from a neutral
position to a compressed position.
[0224] Example 25 includes the method of Example 24, wherein moving
the compaction surface from the neutral position to the compressed
position includes manually moving the compaction surface from the
neutral position into the compressed position against a spring
force generated by a spring of the welding tool, wherein the spring
is operatively positioned between the compaction foot and the
housing, and wherein the spring biases the compaction foot into the
neutral position.
[0225] Example 26 includes the method of any of Examples 24-25,
wherein the compaction surface is positioned flush with or below
the stabilization surface when the compaction surface is in the
compressed position.
[0226] Example 27 includes the method of any of Examples 16-18,
wherein welding the first thermoplastic part to the second
thermoplastic part includes moving the welding surface along the
central axis of the welder from a retracted position to an extended
position.
[0227] Example 28 includes the method of Example 27 wherein moving
the welding surface from the retracted position to the extended
position includes automatically moving the welding surface from the
retracted position into the extended position by delivering
pressurized air in a controlled manner to an air cylinder located
within the housing, wherein the air cylinder is movable along the
central axis of the welder, and wherein the welder is fixedly
coupled to the air cylinder.
[0228] Example 29 includes the method of any of Examples 27-28,
wherein the welding surface is positioned above the stabilization
surface when the welding surface is in the retracted position, and
wherein the welding surface is positioned flush with or below the
stabilization surface when the welding surface is in the extended
position
[0229] Although certain example methods, apparatus and articles of
manufacture have been disclosed herein, the scope of coverage of
this patent is not limited thereto. On the contrary, this patent
covers all methods, apparatus and articles of manufacture fairly
falling within the scope of the claims of this patent.
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