阅读说明：本技术 用于电阻焊接热塑性部件，特别是用于飞行器生产，的加热元件、装置和方法，以及飞行器 (Heating element, device and method for resistance welding thermoplastic parts, in particular for aircraft production, and aircraft ) 是由 M·蒂尔亚基 W·艾尔肯 A·巴赫拉尼 于 2019-08-16 设计创作，主要内容包括：用于电阻焊接飞行器的热塑性部件的加热元件(30)包括以线或纤维形式的导电元件(30a),其在向加热元件(30)施加电压时加热,以在由加热元件(30)电加热的区域中将第一部件(11)焊接到第二部件(12)。导电元件(30a)在接触区域(35、36)之间彼此平行地延伸,用于电接触加热元件(30)。在焊接过程之后,加热元件(30)保留在焊接部件(11、12)之间,以增强焊接结合部的强度。一种用于通过电阻焊接结合热塑性部件的装置包括加热元件(30)和滚柱电极形式的单元(31、32),该单元用于沿焊接方向移位部件(11、12)的电加热区域。导电元件(30a)平行于滚柱电极的旋转轴(31a、32a)延伸。(A heating element (30) for resistance welding thermoplastic parts of an aircraft comprises an electrically conductive element (30a) in the form of a wire or fibre which heats up when a voltage is applied to the heating element (30) to weld a first part (11) to a second part (12) in an area which is electrically heated by the heating element (30). The electrically conductive elements (30a) extend parallel to each other between the contact areas (35, 36) for electrically contacting the heating element (30). After the welding process, a heating element (30) remains between the welded components (11, 12) to enhance the strength of the welded joint. An apparatus for joining thermoplastic parts by resistance welding comprises a heating element (30) and a unit (31, 32) in the form of a roller electrode for displacing an electrically heated region of the parts (11, 12) in the welding direction. The conductive element (30a) extends parallel to the rotational axes (31a, 32a) of the roller electrodes.)

1. Heating element for resistance welding thermoplastic parts, in particular for producing aircraft, comprising one or more electrically conductive elements (30a), which electrically conductive elements (30a) are heated when a voltage is applied to the heating element (30) in order to weld a first part (11) to a second part (12) in a region which is electrically heated by the heating element (30), wherein the heating element (30) is designed to remain between the welded parts (11, 12) after the welding process and to form a reinforcement in order to reinforce the strength of the weld joint therein,

and wherein the electrically conductive elements (30a) are designed as wires or fibers, the electrically conductive elements (30a) extending parallel to one another between contact regions (35, 36) for electrically contacting the heating element (30).

2. A heating element according to claim 1, characterized in that the electrically conductive elements (30a) in the heating element (30) are aligned in the direction of the main load, which acts on the parts (11, 12) to be welded to each other.

3. Heating element according to claim 1 or 2, characterized in that the electrically conductive elements (30a) extend electrically insulated from each other between the contact areas (35, 36) of the heating element (30).

4. Heating element according to any one of the preceding claims, characterized in that the orientation of the electrically conductive element (30a) is oriented perpendicularly to the direction X of the weld seam to be produced.

5. Heating element according to any of the preceding claims, characterized in that at least one contact surface (35, 36) is intended to contact an electrode (31, 32) that is movable relative to the heating element (30).

6. Device for joining thermoplastic parts by resistance welding, in particular for producing an aircraft, comprising a heating element (30) according to any one of the preceding claims, and

a unit (31, 32) for displacing an electrically heated region of a component (11, 12) along the component (11, 12) in a welding direction W.

7. The device according to claim 6, characterized in that the unit (31, 32) for displacing the electric heating area comprises one or more contact elements (31, 32), the contact elements (31, 32) being movable relative to the heating element (30) to continuously contact the heating element (30) at different points.

8. Device according to claim 7, characterized in that the contact elements (31, 32) are designed as roller electrodes which roll on the heating element (30) during welding, in order to continuously supply each partial region of the heating element (30) with a continuous current.

9. Device according to claim 8, characterized in that the electrically conductive element (30a) of the heating element (30) extends parallel to the rotational axis (31a, 32a) of the roller electrode (31, 32).

10. Device according to any one of the preceding claims, characterized in that one or more contact pressure elements (41, 42) press the first part (11) and the second part (12) against each other during welding in a contact pressure zone which moves synchronously with the electrically heated zone.

11. Method for joining thermoplastic parts, in particular for producing an aircraft, by resistance welding, in which method,

welding the first component (11) to the second component (12) on an electrically heated region of the components (11, 12), wherein electrically conductive elements (30a) of the heating element (30) are designed as wires or fibers, said electrically conductive elements (30a) extending parallel to one another between contact regions (35, 36) for electrically contacting the heating element (30), and

after the welding process, the heating element (30) remains between the welded components (11, 12) and forms a reinforcement therein to enhance the strength of the welded joint.

12. Method according to claim 11, characterized in that said conductive elements (30a) are aligned in the direction of the main load acting on said parts (11, 12) welded to each other.

13. Method according to claim 11 or 12, characterized in that the electrically heated area of the component (11, 12) is moved in relation to the component (11, 12) in a welding direction W during the welding.

14. Method according to any one of claims 11 to 13, characterized in that one electrode (31, 32) is moved in a welding direction W and continuously supplies an electric current to the respective partial region of the heating element (30), wherein the electrically conductive elements (30a) extend electrically insulated from one another and continuously extend perpendicularly to the welding direction W.

15. An aircraft, comprising a component, the component:

-providing a heating element (30) according to any one of claims 1 to 5; and/or

Welding using the device according to any one of claims 6 to 10; and/or

Produced using a method according to any one of claims 11 to 14.

Technical Field

The invention relates to a heating element for resistance welding thermoplastic components, in particular for producing aircraft. The invention further relates to a device and a method for joining thermoplastic parts by resistance welding, in particular for producing an aircraft, and to an aircraft.

Background

Components made of composite and/or fiber composite materials are increasingly being used for configuring modern aircraft and/or aircraft. The individual components are connected to one another, for example by riveting, adhesive, screws or welding.

The fuselage of an aircraft usually comprises a fixed frame made of stiffening elements, which supports a skin made of composite material. Stringers and frames serve as reinforcing elements, wherein the stringers extend in the longitudinal direction of the fuselage and the frames extend in the circumferential direction of the fuselage. During the production of an aircraft fuselage, the individual fuselage sections are usually produced separately from one another and subsequently joined together to form the entire fuselage.

The overlapping skin portions of the segments are often joined using rivets. However, the rivet connection is point-like and thus may cause a concentration of tension. Rivet connections are complex to produce.

In the case of adhesives, the adhesive surface has to be prepared in a complicated manner and curing of the adhesive used requires a high expenditure of time. In the case of connecting components by means of screws, drilling is required, whereby disadvantages may affect the structure of the respective component.

Document DE 102015110193 a1 describes a method for welding two parts made of thermoplastic composite material having multiple layers.

Document DE 102007003357 a1 describes the bonding of thermoplastic materials to fiber composites by means of movement welding or induction welding. For induction welding, the electrically conductive material is arranged in the joining region between the thermoplastic material and the fibre composite material.

Document EP 3040265 a1 describes a method for connecting two fuselage sections. In this case a connection frame is used.

Fig. 2 shows a known method of joining components by resistance welding. In this case, the first member 110 and the second member 120 are coupled to each other. For this purpose, an electrically conductive heating element 130 is arranged between the components 110, 120 along the welded portion in order to generate heat in the bonding area. For this purpose, the heating element 130 is connected on both sides to electrical connection clamps 131, 132, which electrical connection clamps 131, 132 are connected to a voltage source to generate an electrical current through the heating element 130. The voltage and current applied to the heating element 130 were measured.

In the case of joining individual fuselage sections of an aircraft, the welded joint must be subjected to very high loads. Particularly in the case of fuselage lengths, for example in the range of 24 meters, a correspondingly long and very strong joint of the fuselage sections must be produced.

Furthermore, when joining the individual fuselage sections by means of resistance welding, there is the further problem that the welded joint must be produced over a long length. In the case of fuselage lengths (which may be in the range of 24 meters, for example), correspondingly long welded joints of overlapping skin sections of fuselage sections joined to one another must be produced. However, current losses may occur during resistance welding over long lengths, which results in an inefficient heating process. Also, the weld joint may be rendered uneven or defective. Furthermore, long distance welding requires high power consumption.

Disclosure of Invention

The object of the invention is to join thermoplastic parts over a length of increased strength by resistance welding, for example as required in aircraft production, in particular in the welding of fuselage sections. In particular, fuselage sections of commercial aircraft can be welded, wherein a high-quality and high-strength joint is ensured.

In order to achieve this object, the invention provides a heating element for resistance welding thermoplastic components, in particular for producing aircraft, comprising one or more electrically conductive elements which are heated when a voltage is applied to the heating element in order to weld a first component to a second component in a region which is electrically heated by the heating element, wherein the heating element is designed to remain between the welded components after the welding process and to form a reinforcement to increase the strength of the welded joint therein, and wherein the electrically conductive elements are designed as wires or fibers which extend parallel to one another between the contact regions for electrically contacting the heating element.

Large components can also be joined with high strength and low time consumption by means of a multifunctional heating element for resistance welding. In particular, in the production of aircraft, large fuselage sections can also be joined to one another to produce a fuselage with increased strength at the connecting seam.

The electrically conductive elements in the heating element are preferably aligned in the direction of the main load, which acts in particular on the components welded to one another in the mounted state of the welded components. In particular, the main load may be a traction force, which pulls apart the welding part in the mounted state.

The electrically conductive elements or fibers are aligned, for example, in the load direction of the solder joint to be produced.

In particular, the heating element and/or its electrically conductive fibers serve as reinforcing elements for components that are welded to one another after the welding process.

The electrically conductive elements advantageously extend electrically insulated from one another between the contact regions of the heating element.

The orientation of the conductive element is advantageously oriented perpendicular to the direction X of the weld seam to be produced.

For example, the heating element comprises at least one contact surface for contacting an electrode that is movable relative to the heating element.

The partial region defined in the heating element is preferably heatable by means of an electric current, the position of which in the heating element is variable during the welding process.

In particular, the heating element is located in a region outside the defined partial region, and is not heated thereby due to the current in the electrically conductive element arranged there.

The heating element is used in particular for welding a first component comprising thermoplastic material to a second component comprising thermoplastic material in a region which is electrically heated by the heating element.

The conductive elements are advantageously formed as carbon fibers.

The electrically conductive element advantageously extends beyond the heating element and forms a contact element there for the power supply.

In particular, these components are elements of an aircraft fuselage which are to be joined along a weld seam, wherein the main load is oriented, for example, perpendicular to the direction X of the weld seam. This may be the case, for example, in an aircraft fuselage longitudinal seam.

The present invention provides a multifunctional heating element which on the one hand serves to heat the weld zone during resistance welding and on the other hand forms a structural-mechanical reinforcement of the parts welded to each other. In particular, the orientation of the fibers of the heating element in the direction of the main stress or main load enables an increased load transfer capacity.

According to one aspect of the invention, a system or a device for joining thermoplastic parts by resistance welding is provided, which is particularly suitable for producing aircraft, wherein the device comprises a heating element according to the invention and particularly also a unit for displacing an electrically heated region of the part in the welding direction W along the part.

The weld joint of the thermoplastic component is thus realized in particular over a high-quality length, as is required, for example, in aircraft production, wherein the power consumption is additionally reduced and the time consumption is reduced. For example, the entire fuselage section can be joined in the longitudinal direction by welding, wherein a high quality and strength of the joint is ensured, the power consumption is reduced, and the time consumption is reduced.

Advantageously, the electrically heated region of the component is heated by a partial region of the heating element, wherein the position of the partial region in the heating element is changed during the welding process. In particular, in this case, the position is constantly changing. In particular, the unit for displacing the electric heating area during welding continuously supplies a continuous current to different partial areas of the heating element to enable the heating area to be performed or to be performed continuously.

The unit for displacing the electric heating field preferably comprises one or more contact elements which are movable relative to the heating element for continuously electrically contacting the heating element at different points.

The heating element may thus be in continuous contact and/or provide a continuous current at different areas or points during the welding process.

In particular, the contact element is in contact with the heating element during its movement and serves as a power source for the heating element. They are designed, for example, as electrodes.

The contact element is advantageously designed as a roller or roller electrode which rolls on the heating element during the welding process in order to continuously supply the respective partial region of the heating element with a continuous current.

The electrically conductive elements of the heating element advantageously extend parallel to the axis of rotation of the roller electrode. During the welding process, therefore, only locally defined, welded points are heated in the entire joint region, at which the components lie against one another or overlap one another.

For example, the device comprises one or more contact pressure elements to press the first and second parts against each other in a contact pressure area during welding, wherein the contact pressure area is movable in synchronization with the electrically heated area. The components can thus be pressed together in a targeted manner in the respective heating region in order to weld them to one another in this way.

In particular, the first and/or the second contact-pressure element is designed as a movable contact-pressure roller, or it may comprise one or more contact-pressure rollers.

In particular, devices and/or systems for resistance welding thermoplastic parts have a contact pressure unit to press the thermoplastic parts against each other during welding.

The device and/or system advantageously comprises at least one movable electrode which is moved over the contact surface of the heating element during welding to continuously provide a continuous current to the respective partial region of the heating element. In particular, the movable electrode is in this case designed as a roller, which rolls on the contact surface of the heating element during welding.

In particular, a device and/or a system for joining thermoplastic parts by resistance welding is provided, which is suitable for producing aircraft and comprises a heating element according to the invention.

According to another aspect of the invention, a device for joining thermoplastic parts by resistance welding is proposed, which is particularly suitable for producing aircraft, comprising: welding a first part comprising thermoplastic material to an electrically conductive heating element of a second part comprising thermoplastic material in an electrically heated region of the parts, and a unit for continuously displacing the electrically heated region of the parts in a welding direction W along the parts.

According to another aspect of the invention, a method of joining thermoplastic parts by resistance welding is provided, which is particularly suitable for producing aircraft, wherein a first part is welded to a second part in an electrically heated region of the parts. Wherein the electrically conductive elements of the heating element are present as wires or fibers extending parallel to each other between the contact areas for electrically contacting the heating element, and the heating element remains between the welded parts after the welding process and forms a reinforcement therein to enhance the strength of the welded joint.

The conductive elements are advantageously aligned in the direction of the main load acting on the components welded to each other.

Preferably, the electrically heated area of the component is moved relative to the component in the welding direction W during welding.

Different partial regions of the heating element advantageously provide a continuous current during the welding process to effect movement of the electrically heated region (also referred to as the weld region) relative to the component.

The electrode is advantageously moved in the welding direction W and continuously supplies a continuous current to the respective partial regions of the heating element, wherein the electrically conductive elements extend, for example, electrically insulated from one another and perpendicularly to the welding direction W.

For example, during welding, one or more contact elements or electrodes for the current supply of the heating element are moved relative to the heating element to continuously contact the heating element at different points.

The contact element is preferably in continuous electrical contact with the heating element during its movement.

During the welding process, the first part and the second part are advantageously pressed against each other in a contact pressure region, wherein in particular the contact pressure region moves relative to the part synchronously with the electric heating region.

One or more contact pressure rollers are preferably moved over the parts to be welded in order to press the parts against each other in the welding area during welding.

Furthermore, the device described herein is used for joining components, in particular fuselage sections of aircraft.

In particular, the method is carried out using a heating element according to the invention and/or using a device according to the invention.

According to a further aspect of the invention, a method for joining thermoplastic parts by resistance welding is proposed, which method is particularly suitable for producing aircraft, wherein a first part comprising thermoplastic material is welded to a second part comprising thermoplastic material in an electrically heated region of the parts, wherein the electrically heated region of the parts is moved relative to the parts in a welding direction W during the welding process.

According to a further aspect of the invention, a method for joining thermoplastic parts by resistance welding is proposed, in particular for producing aircraft, wherein a first part comprising thermoplastic material is welded to a second part comprising thermoplastic material in an electrically heated region of the parts, wherein a heating element remains between the welded parts after the welding process and forms a reinforcement or stiffening element there in order to reinforce the strength of the weld joint of the parts welded to one another.

According to a further aspect, the invention provides an aircraft having a component provided as a heating element according to the invention and/or being welded or produced using a device according to the invention or a method according to the invention.

Furthermore, an aircraft is provided, which is produced using the above-described device and/or using the above-described method.

In particular, the fuselage of an aircraft is produced in this way.

In particular, by means of the invention, during the production of an aircraft, fuselage sections can be quickly and reliably joined to one another in order to produce a fuselage. Furthermore, power consumption and current consumption during resistance welding are reduced. The power loss is minimized, since the heating takes place continuously, in particular in the respective locally defined weld zone. Furthermore, improved tolerance management can be achieved, in particular for very long solder joints. In particular, the welding process can be better controlled during continuous resistance welding. Furthermore, production time is saved by the various advantages of the present invention.

The advantages and details described in connection with the heating element according to the invention also apply to the device according to the invention and to the method according to the invention, and the advantages and details described in connection with the device according to the invention or the method according to the invention also apply to the heating element according to the invention.

Drawings

Exemplary embodiments of the present invention will be explained in more detail below based on the drawings. In the drawings:

fig. 1 schematically shows a sectional view of a preferred embodiment of a system according to the invention with a heating element according to the invention during the production of an overlap joint in the region of an aircraft fuselage;

FIG. 2 shows a schematic view of a known apparatus for resistance welding;

figures 3a and 3b schematically show a top view of the preferred embodiment of the invention shown in figure 1 during production of a weld joint of two overlapping parts;

figure 4 shows a cross-section of a multifunctional heating element according to the invention;

FIG. 5 shows a flow chart showing the steps of a method according to the invention;

FIG. 6 shows a side view of an aft fuselage section of a commercial aircraft having longitudinal seams welded in accordance with the present invention;

FIG. 7 shows a cross-sectional view of the fuselage section shown in FIG. 6 with longitudinal seams welded in accordance with the present invention;

fig. 8 shows a cross-sectional view of a longitudinal seam of a commercial aircraft welded according to the invention.

Detailed Description

Fig. 1 shows a cross-sectional view of a system or device for joining thermoplastic parts of an aircraft by means of resistance welding according to a preferred embodiment of the invention. The apparatus or resistance welding system includes an electrically conductive heating element 30 for welding the first part 11 to the second part 12 in an electrically heated region of the parts.

The parts 11, 12 to be welded comprise thermoplastic material and are arranged in the overlapping area on both sides of the heating element 30 for resistance welding.

The heating element 30 comprises an electrically conductive element 30a, which electrically conductive element 30a is formed as a wire and/or a fibre for heating the components 11, 12 when a voltage is applied (see also fig. 3a and 3 b). The heating element 30 is designed to remain in the weld joint after the welding process and to permanently serve therein as a reinforcing element for the components 11, 12 welded to one another.

The heating element 30 thus performs two functions. On the one hand, it serves as a heating element for resistance welding and, on the other hand, by means of its conductive element 30a, it serves as a structural and/or structural-mechanical reinforcement of the component produced by welding. During resistance welding, the thermoplastic material is melted, wherein at the bonding points the thermoplastic material of the parts 11, 12 encapsulates the wires or fibers 30a of the heating element 30 as a matrix, thereby creating a fiber-reinforced bond.

The electrically conductive fibers or wires 30a of the heating element 30 are aligned in the main load direction M of the solder joint to be produced (see fig. 3 a). They are present as carbon fibers and/or are made of carbon materials.

The heating element 30 is positioned during the welding between the two parts 11, 12 so as to locally heat them by means of an electric current in its conductive element or fibre 30 a. In this example, the parts 11, 12 to be joined are each skin (skin) parts of fuselage sections and comprise a thermoplastic material. For welding, they are arranged adjacent to each other, wherein they are positioned one on top of the other in the overlapping area.

The heating element 30 is formed as a plane and extends between the two components 11, 12 to be joined in the longitudinal direction L or in the X direction, which extends perpendicular to the drawing plane in fig. 1. The conductive element 30a or the fiber or wire heats up upon application of a voltage due to the current generated therein (see fig. 3a and 3 b).

Two contact elements in the form of movable electrodes 31, 32 are connected to a voltage source 50 and are used to apply a voltage to the heating element 30. The electrodes 31, 32 are designed to be movable relative to the heating element 30. The movement of the electrodes 31, 32 takes place perpendicular to the surface of the figure, i.e. in the longitudinal direction L of the heating element 30 (see fig. 3 b).

In each case, the electrodes 31, 32 contact the planar heating element 30 at contact regions 35 or 36, respectively, to generate an electric current between the two electrodes 31, 32 by means of the heating element 30. The contact areas 35, 36 are located at the left and right edge areas of the heating element 30, and the heated current flows only between the opposing electrodes 31, 32 in the width direction of the heating element 30 (i.e., left to right or right to left as viewed in fig. 1).

The two contact elements formed as movable electrodes 31, 32 form a cell in the following way: this unit serves to heat a locally defined partial region of the heating element 30 and to move or displace it continuously along the parts 11, 12 during the welding process, while the heating element 30 is fixed in position between the parts 11, 12 to be welded. The unit thus continuously displaces the heating areas of the components 11, 12 along the components 11, 12 during the welding process. In this case, regions of the heating element 30 which lie outside the locally defined displaceable partial region are not supplied with current.

The region or partial region heated by the current in the electrically conductive element 30a forms a welding region in which the two parts 11, 12 are welded to one another by melting the thermoplastic material and subsequently solidifying by applying pressure.

The movable electrodes 31, 32 are designed as rollers. The rollers or roller electrodes 31, 32 are applied to the heating element 30 during welding such that a portion of the outer circumferential surface of each of them is brought into contact with the heating element 30, while they roll on the respective contact surface of the heating element 30.

On the first side of the heating element 30 or on the side lying at the top in fig. 1, the heating element 30 is in electrical contact with the first electrode 31 in a contact region 35 lying at the right in fig. 1, which contact region 35 is a partial region or edge region of the heating element 30 and extends on the right edge of the heating element 30 on its top side in the longitudinal direction L (X direction) of the heating element 30 (i.e. perpendicular to the drawing plane in fig. 1) (see also fig. 3a and 3 b).

On the second side of the heating element 30 or on the side located at the bottom in fig. 1, the heating element 30 is in electrical contact with the second electrode 32 in a contact region 36 located at the left in fig. 1, which contact region 36 extends on the left edge of the heating element 30 on its bottom side in the longitudinal direction L of the heating element 30.

The contact points in the contact areas 35, 36 are formed by the respective outer circumferential surfaces of the roller-shaped electrodes 31, 32 applied to the heating element 30.

Since the roller-shaped electrodes 31, 32 roll on the heating element 30 at the contact regions 35 or 36, respectively, the electrically conductive part region of the heating element 30 between the two electrodes 31, 32 is displaced in the longitudinal direction of the heating element 30, which extends perpendicular to the drawing plane of fig. 1. The electrically heated soldering zone is heated by a corresponding electrically conductive, locally defined partial region of the heating element 30 and thus proceeds continuously in the longitudinal direction (X-direction). This movement corresponds to the welding movement W.

The two components 11, 12 to be joined to each other are arranged on opposite sides of the heating element 30, i.e. on the top side or the bottom side thereof, respectively. The two parts 11, 12 are formed by skin sections of fuselage sections or various fuselage sections. In this example, the top skin element forms the component 11, while the bottom skin element forms the component 12.

In the contact pressure region during the welding process, the two skin portions or sections 11, 12 are pressed against each other by means of two opposing contact pressure elements in the form of contact pressure rollers 41, 42. In the example shown here, the contact-pressure element 41 arranged above the first component 11 exerts a force directed downwards in the direction of the welding area on the first or top component 11, while the contact-pressure element 42 arranged below the second component 12 exerts an opposite force directed upwards in the direction of the welding area on the second or bottom component 12.

In operation, the two contact pressure elements or contact pressure rollers 41, 42 are moved synchronously with the welding zone being carried out, so that the two parts 11, 12 to be welded to one another are pressed against one another in the respective heated, electrically conductive partial regions of the heating element 30.

Fig. 3a and 3b show a resistance welding system or an arrangement with a heating element 30 according to the invention, while in the upper view a welding process is performed, which is indicated by arrow a in fig. 1.

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

The first or top roller electrode 31 is located adjacent the right side of the top or first contact pressure roller 41. Which is in electrical contact with the top side of the contact area 35 of the heating element 30 located therebelow.

The bottom or second electrode 32 is located adjacent to the bottom or second contact pressure roller 42 on the left, which is not visible in fig. 3a and 3 b. Which is in electrical contact with the underside of the contact region 36 of the heating element 30 located above it.

The two electrodes 31, 32 thus contact the top side or the bottom side, respectively, of the heating element 30, each electrode being located on a surface area of the heating element 30 which is laterally located in the contact pressure area or the overlap area.

The two electrodes 31, 32 contact the heating element 30 on two opposite contact areas 35, 36, respectively, on respective edges of the heating element 30. The contact areas 35, 36 of the heating element 30 are located laterally in the vicinity of the overlapping area of the parts 11, 12. The width of the respective edge or contact area 35, 36 substantially corresponds to the width of the outer circumferential surface of the respective roller electrode 31 or 32.

The width of the heating element 30 is greater than the width of the overlapping regions of the skin portions or components 11, 12. Contact areas 35, 36 for contacting the electrodes 31, 32 are thus formed on both sides of the heating element 30.

In order to locally join the heated soldering zones in the longitudinal direction L or X-direction (i.e. in the direction of the soldering movement W), the electrically conductive elements 30a or wires of the heating element 30 extend substantially parallel to one another and are electrically insulated from one another in the longitudinal direction L between the contact zones 35, 36 on both sides of the heating element 30.

The conductive element 30a extends parallel to the respective rotational axes 31a, 32a of the roller electrodes 31, 32 and parallel to the rotational axes 41a, 41b of the roller-shaped contact- pressure elements 41, 42. The current between the two roller-shaped electrodes 31, 32 extends through the heating element 30, which heating element 30 is substantially parallel to the respective rotational axes 31a, 32a of the roller electrodes 31, 32 and also to the rotational axes 41a, 41b of the roller-shaped contact pressure elements 41, 42.

The overlapping fuselage shown in fig. 3a and 3b, which joins the two skin sections 11, 12, extends in the X direction, which in the case of a longitudinal seam of the fuselage corresponds to the longitudinal direction of the aircraft fuselage. The Y direction perpendicular to its orientation corresponds to the peripheral direction of the fuselage and in this case is the direction of the main load or main load direction M, in which the greatest strain occurs on the joints between the fuselage sections.

The direction of the fibers 30a arranged in the heating element 30, which fibers 30a are made of an electrically conductive material and are provided as carbon fibers, can be selected according to the respective load distribution.

Fig. 4 shows a cross-sectional view of a multifunctional heating element 30 according to a preferred embodiment as part of a device according to the invention or a system for resistance welding according to the invention. The insulator 34 is arranged on the top side and the bottom side thereof and between the conductive fibers 30. In this case, an adhesive is used as the insulator. The conductive fibers 30a extend in all directions in the heating element 30.

The electrically conductive elements or fibres 30a extend at their respective ends into electrically conductive terminal elements 37, 38, which terminal elements 37, 38 are located at each of the two ends of the heating element 30 to the right and left in the figure. The element thus extends beyond the heating surface of the heating element 30 so that its two ends are inserted into the terminal elements 37 or 38, respectively, and fixed therein. The terminal elements 37, 38 are made of metal and/or metal parts, for example. During welding they form contact surfaces 35, 36 on which the electrodes 31, 32 move or on which the electrodes 31, 32, which are formed as rollers, roll on the contact surfaces 35, 36.

The joint of the two components 11, 12 according to the invention is described below by way of example on the basis of figures 1, 3a, 3b and 5. The joint of the two components 11, 12 serves as a skin section of the fuselage section of the aircraft.

The first skin section 11 is arranged on the second skin section 12 such that the two skin sections overlap in a partial region. The planar heating element 30 is arranged between the two overlapping skin sections 11, 12. The planar heating element 30 comprises electrically conductive wires or fibres 30a which are heated during the welding process to melt the thermoplastic material of the parts 11, 12 in the welding zone and which additionally serve as reinforcing elements for the parts 11, 12 welded to each other after the welding process. The threads or fibers 30a of the heating element 30 are made of carbon or are designed as carbon fibers. They are arranged for welding the components 11, 12 such that they are aligned in the main load direction M, the main load acting on the weld joint of the components 11, 12 that are welded to each other in the mounted state. (step 1)

In order to form a weld zone which is locally defined in the welding direction, the heating element 30 is now supplied with current via the movable electrodes 31, 32. This takes place only in a partial region of the heating element 30 which is locally defined in the longitudinal direction. This means that the heating element 30 conducts current in the Y-direction (i.e. perpendicular to the longitudinal direction L or the welding direction W), in the joining region or in a welding region locally defined in the longitudinal direction L (X-direction) by contact with the electrodes 31, 32, while the remaining region of the heating element 30 is not supplied with current.

During welding, the electrodes 31, 32 are moved in the longitudinal direction L of the joint or the heating element 30 (i.e. in the welding direction W) while being in continuous electrical contact with the heating element 30 or with the partial areas or conductive elements 30a in contact with the electrodes 31, 32, respectively. In this way, the locally defined welding zone is moved in the heating element 30 in the welding direction W or in the direction of the welding movement (X-direction), which corresponds to the longitudinal direction L of the planar heating element 30 or weld seam. In this case, the heating element 30 is held fixedly in place between the two skin portions 11, 12. (step 2)

The contact pressure rollers 41, 42 pressing the two skin portions 11, 12 against each other during welding move synchronously with the moving electrodes 31, 32.

After being welded together, the heating element 30 remains in the weld.

When performing the method, the various parameters required for the welding process are taken into account. For example, the welding speed is preferably 100 to 350 millimeters (mm)/minute. Ceramic insulators are preferably used as the contact pressure elements 41, 42, whereby heat losses are reduced. For example, the pressure may be in the range of about 6 bar. The shear strength of the bond may be, for example, about 58N/mm². In many cases the skin thickness of the parts or fuselage sections to be welded is in the range of 2 to 3 mm. However, they may also be larger and may be, for example, 6mm or more, for example, in the vicinity of the door cut of the fuselage section.

In fig. 6 a side view of an aft fuselage section 80 of a commercial aircraft with a longitudinal seam 81 welded according to the invention is shown.

In fig. 7 a cross section of the fuselage portion 80 shown in fig. 6 is shown with the location of the longitudinal seam 81 welded according to the invention.

Fig. 8 shows a cross-sectional view of a longitudinal seam 81 of a commercial aircraft welded according to the invention with overlapping skin sections 11, 12. The first skin section 11 arranged on top of the fuselage section overlaps the area of the second skin section 12 arranged on the bottom. The heating element 30 is located between the two skin portions.

After being welded together, the heating element 30 may remain in the seam 81. In this case, it is particularly advantageous if the heating element 30 has fibers, in particular carbon fibers, as the electrically conductive elements 30 a. The fibers are arranged for welding such that they are aligned in the load direction along the main load direction of the welded joint to be produced. The heating element 30 or its fibres are therefore used as reinforcing elements for the welded components 11, 12 after the welding process.

The heating elements, devices and methods described above represent particularly preferred embodiments of the invention. In certain applications, it is also possible, for example, to design only one contact-pressure element as movable or as a roller, while the other, opposite contact-pressure element is stationary and forms a fixed contact-pressure surface, for example, below the overlap region of the two parts 11, 12.

Furthermore, in certain cases, it is possible, for example, to design only one electrode as movable or as a roller, while the other electrode is stationary and contacts the region of the heating element 30 in a planar manner. The movable electrode may also be formed, for example, as a sliding contact.

By thermoplastic welding, the present invention results in a weld joint area with increased strength relative to conventional joints, where only a thermoplastic matrix is used to join the components. In particular, in this way very long components (in particular fuselage sections of aircraft or commercial aircraft) can be joined to one another by means of resistance welding.

With the invention, instead of heating the entire length of the welded joint to be produced immediately, continuous heating is carried out during resistance welding by means of one or more movable elements. Thus reducing power consumption and current consumption during resistance welding.

Since the heating which takes place continuously only locally at the location of the currently heated weld zone, the power loss is minimized. In particular, very long parts (in particular fuselage sections) can be joined to one another by means of resistance welding. The tolerances of the long parts to be welded can be better handled. Due to the continuous resistance welding, the welding process can be better controlled.

Furthermore, by the method according to the invention, in particular using a multifunctional heating element, the time consumption during production of the aircraft fuselage is reduced.

List of reference numerals

11 first component/first skin component

12 second part/second skin part

30 heating element

30a conductive elements or fibres

31. 32 contact element/electrode

31a, 32a rotary shaft

34 insulator

35. 36 contact area

37. 38 terminal element

41. 42 contact pressure element or contact pressure roller

41a, 42a rotation axis

50 voltage source

80 fuselage section

81 longitudinal seam

L longitudinal direction

M main load or main load direction

W welding direction

In the X longitudinal direction

Y transverse or peripheral direction

110. 120 parts

130 heating element

131. 132 connecting clamp

133 voltage source