US 12,434,445 B2
Methods for joining a first thermoplastic substrate with a second thermoplastic substrate
Ying Shi, Saint Louis, MO (US); Alexander M. Rubin, St. Louis, MO (US); and Gregory J. Hickman, University City, MO (US)
Assigned to The Boeing Company, Arlington, VA (US)
Filed by The Boeing Company, Chicago, IL (US)
Filed on Feb. 2, 2022, as Appl. No. 17/590,879.
Claims priority of provisional application 63/152,922, filed on Feb. 24, 2021.
Prior Publication US 2022/0266541 A1, Aug. 25, 2022
Int. Cl. B29C 65/00 (2006.01); B29C 65/02 (2006.01); B32B 27/08 (2006.01); B32B 27/28 (2006.01); B32B 37/04 (2006.01); B32B 37/10 (2006.01); B32B 37/18 (2006.01); B29K 71/00 (2006.01)
CPC B29C 66/73116 (2013.01) [B29C 65/02 (2013.01); B29C 66/73921 (2013.01); B32B 27/08 (2013.01); B32B 27/285 (2013.01); B32B 27/288 (2013.01); B32B 37/04 (2013.01); B32B 37/10 (2013.01); B32B 37/182 (2013.01); B29K 2071/00 (2013.01); B29K 2995/004 (2013.01); B32B 2309/02 (2013.01); B32B 2309/12 (2013.01); B32B 2371/00 (2013.01)] 24 Claims
OG exemplary drawing
 
1. A method for joining a first multi-ply thermoplastic composite part with a second multi-ply thermoplastic composite part, the method comprising:
co-consolidating a first semicrystalline thermoplastic film with the first multi-ply thermoplastic composite part to yield a first co-consolidated structure, the first multi-ply thermoplastic composite part comprising a first polyaryletherketone material having a first melting temperature, the first semicrystalline thermoplastic film comprising a second polyaryletherketone material having a second melting temperature, the second melting temperature being less than the first melting temperature, wherein the first semicrystalline thermoplastic film defines a first bonding surface on a first side of the first co-consolidated structure;
co-consolidating a second semicrystalline thermoplastic film with the second multi-ply thermoplastic composite part to yield a second co-consolidated structure, the second multi-ply thermoplastic composite part comprising the first polyaryletherketone material, the second semicrystalline thermoplastic film comprising a third polyaryletherketone material having a third melting temperature, the third melting temperature being less than the first melting temperature, wherein the second semicrystalline thermoplastic film defines a second bonding surface on a second side of the second co-consolidated structure;
positioning the first co-consolidated structure and the second co-consolidated structure such that the first bonding surface is facing the second bonding surface; and
fusing the first bonding surface on the first side of the first co-consolidated structure to the second bonding surface on the second side of the second co-consolidated structure to yield a semicrystalline film joined thermoplastic assembly.