Granted Patent B2

US 12,636,842 · App. 18/227,691 · Granted May 26, 2026

Inventors: Shyan Bob Shen (San Diego, CA); Michael van Tooren (San Diego, CA); Keith E. Ritchie (San Diego, CA); Daniel O. Ursenbach (El Cajon, CA)

Assignee: Rohr, Inc.

B29C73/10B29C65/08B29C65/72B29K2105/06B29L2031/3076

Abstract

Claims (44)

1 . A repair method, comprising:

arranging a thermoplastic patch on a thermoplastic aerospace component, the thermoplastic patch contacting the thermoplastic aerospace component, the thermoplastic aerospace component including an aperture, an exterior surface and an interior surface, the aperture extending into the thermoplastic aerospace component from the exterior surface to the interior surface, and the thermoplastic patch disposed in the aperture and contacting the interior surface;

horizontal ultrasonic welding the thermoplastic patch to the thermoplastic aerospace component using an ultrasonic horn;

arranging a second thermoplastic patch in the aperture, the second thermoplastic patch contacting a surface of the thermoplastic patch; and

horizontal ultrasonic welding the second thermoplastic patch to the thermoplastic patch using the ultrasonic horn.

2 . The repair method of claim 1 , wherein

the ultrasonic horn extends along a centerline;

a face of the ultrasonic horn extending longitudinally along the centerline engages the thermoplastic patch; and

the ultrasonic horn moves back and forth along the centerline during the horizontal ultrasonic welding.

3 . The repair method of claim 2 , wherein

the face of the ultrasonic horn contacts a surface of the thermoplastic patch; and

the centerline is parallel to the surface of the thermoplastic patch.

4 . The repair method of claim 1 , wherein

the thermoplastic patch has a surface that extends between opposing exterior sides of the thermoplastic patch; and

an entirety of the surface contacts the thermoplastic aerospace component.

5 . The repair method of claim 1 , wherein the thermoplastic patch is connected to the thermoplastic aerospace component without use of an adhesive and/or without use of thermoplastic film as an energy director.

6 . The repair method of claim 1 , wherein the thermoplastic patch includes a thermoplastic matrix and fiber-reinforcement embedded within the thermoplastic matrix.

7 . The repair method of claim 1 , wherein the thermoplastic aerospace component includes a thermoplastic matrix and fiber-reinforcement embedded within the thermoplastic matrix.

8 . The repair method of claim 1 , further comprising:

horizontal ultrasonic welding the second thermoplastic patch to the thermoplastic aerospace component using the ultrasonic horn;

the second thermoplastic patch contacting a second interior surface of the thermoplastic aerospace component.

9 . The repair method of claim 1 , further comprising:

arranging a third thermoplastic patch on the exterior surface, the third thermoplastic patch covering the aperture; and

horizontal ultrasonic welding the third thermoplastic patch to the thermoplastic aerospace component using the ultrasonic horn.

10 . The repair method of claim 1 , further comprising removing a damaged portion of the thermoplastic aerospace component to form the aperture.

11 . The repair method of claim 1 , wherein the thermoplastic patch covers a damaged portion of the thermoplastic aerospace component.

12 . The repair method of claim 1 , wherein the thermoplastic patch is horizontal ultrasonic welded to the thermoplastic aerospace component at a plurality of spot weld locations along the thermoplastic patch.

13 . The repair method of claim 1 , wherein the thermoplastic patch is horizontal ultrasonic welded to the thermoplastic aerospace component along an elongated weld seam.

14 . A method, comprising:

removing material from a first thermoplastic body to form an aperture in the first thermoplastic body, the aperture extending into the first thermoplastic body from an exterior surface of the first thermoplastic body to an interior surface of the first thermoplastic body;

arranging a second thermoplastic body in the aperture, the second thermoplastic body contacting the interior surface of the first thermoplastic body;

ultrasonic welding the second thermoplastic body to the first thermoplastic body using an ultrasonic horn, the ultrasonic horn engaging a surface of the second thermoplastic body, and the ultrasonic horn moving back-and-forth along the surface of the second thermoplastic body during the ultrasonic welding of the second thermoplastic body;

arranging a third thermoplastic body in the aperture, the third thermoplastic body contacting the surface of the second thermoplastic body; and

ultrasonic welding the third thermoplastic body to the second thermoplastic body using the ultrasonic horn, the ultrasonic horn engaging a surface of the third thermoplastic body, and the ultrasonic horn moving back-and-forth along the surface of the third thermoplastic body during the ultrasonic welding of the third thermoplastic body.

15 . The method of claim 14 , further comprising:

arranging the third thermoplastic body in the aperture, the third thermoplastic body contacting a second interior surface of the first thermoplastic body; and

ultrasonic welding the third thermoplastic body to the first thermoplastic body using the ultrasonic horn, the ultrasonic horn engaging a surface of the third thermoplastic body, and the ultrasonic horn moving back-and-forth along the surface of the third thermoplastic body during the ultrasonic welding of the third thermoplastic body.

16 . The method of claim 14 , further comprising:

arranging the third thermoplastic body on the exterior surface of the first thermoplastic body, the third thermoplastic body covering the aperture; and

ultrasonic welding the third thermoplastic body to the first thermoplastic body using the ultrasonic horn, the ultrasonic horn engaging a surface of the third thermoplastic body, and the ultrasonic horn moving back-and-forth along the surface of the third thermoplastic body during the ultrasonic welding of the third thermoplastic body.

17 . A method, comprising:

providing a first thermoplastic body with a damaged portion;

arranging a second thermoplastic body on an exterior surface of the first thermoplastic body, the second thermoplastic body covering a damaged portion of the first thermoplastic body; and

ultrasonic welding the second thermoplastic body to the first thermoplastic body using an ultrasonic horn, the ultrasonic horn engaging a surface of the second thermoplastic body, and the ultrasonic horn moving back-and-forth along the surface of the second thermoplastic body during the ultrasonic welding of the second thermoplastic body.

Assignments (1)

Continuity (1)

References Cited (16)