SBIR Phase I: Assembly and Repair of Thermoplastic Reinforced Composites

该小型企业创新研究第一阶段项目将开发一种新的高性能热塑性增强复合材料的辐射焊接方法，而不会使芯纤维材料降解。这种类型的复合材料的常规热焊接方法导致复合芯纤维的降解和焊缝处的强度损失。两个创新的技术集成来实现这一建议。第一个是多层热塑性增强复合结构的开发，以使芯纤维在焊接期间与热暴露隔离。第二种技术是构造焊接单元，该焊接单元在复合材料界面的整个三级结构中投射选择性近红外辐射以焊接复合材料。该技术的更广泛影响可能是可焊接复合材料技术的商业化，以及通过提供可满足大规模生产要求的高速组装和连接工艺，可以显着扩展热塑性增强复合材料（TRC）应用的焊接。基于TRC的部件可以减轻重量，同时保持强度，更容易回收，并使用高速焊接技术组装，将在军事，商业和工业应用中创造新的产品用途。新型薄板TRC正被集成到航空航天制造中，特别是在高空飞艇和气球的建造中。汽车制造商正在寻求更容易回收的轻质复合材料，以降低重量要求，同时保持汽车的强度。用热塑性芯纤维制成的可焊接TRC可以潜在地满足这些需求。扩大使用TRC回收零件将有利于环境。从长远来看，焊接工艺可以提供一种新的具有竞争力的制造技术，可以推动美国经济的就业扩张和增长。

This Small Business Innovation Research Phase I project will develop a new method of radiation welding of high performance thermoplastic reinforced composites without degrading the core fiber material. Conventional methods of thermal welding of this type of composite cause degradation of the composite core fiber and lose of strength at the welding seam. Two innovative technologies are integrated to accomplish this proposal. The first is the development of a multi-layer thermoplastic reinforced composite structure to insulate the core fiber from heat exposure during welding. The second technology is construction of a welding unit that projects selective near infrared radiation throughout the tertiary structure of the composite interface to weld the composites. The broader impacts of this technology could be the commercialization would be weldable composite technology and a welding that could significantly expand applications of thermoplastic reinforced composites (TRC) by providing a high speed assembly and joining process that can meet mass production requirements. TRC based parts that can reduce weight while maintaining strength, be more easily recycled and be assembled using high speed welding technology will create new product uses in military, commercial and industrial applications. New forms of thin sheet TRC are being integrated into the aerospace manufacturing, especially in construction of high altitude airships and balloons. Automobile manufacturers are seeking light-weight composites that are more easily recycled to reduce the weight requirements while maintaining strength in automobiles. Weldable TRC made with a thermoplastic core fiber can potentially meet these needs. Expanded use of TRC recycled parts will benefit the environment. Longer term, the welding process could provide a new competitive manufacturing technology that could drive job expansion and growth in the U.S. economy.