The present disclosure is directed to methods for joining rotor blade components using thermoplastic welding. The method includes arranging a first thermoplastic component and a second thermoplastic component together at an interface, determining a size of a tolerance gap between the first and second components at the interface, placing a thermoplastic insert between the first and second components at the interface, the insert being larger than the tolerance gap, heating the insert and the first and second components such that the insert begins to flow so as to fill the tolerance gap between the first and second components, applying pressure to the interface such that the insert and the first and second blade components remain substantially in direct contact with each other at the interface, and welding the insert and the first and second components together at the interface, wherein the heat and the applied pressure between the insert and the first and second components at the interface maintain the insert and the first and second substantially in direct contact at the interface during welding.

A thermoplastic product includes a fabric-based reinforcing sheet and a polymerized thermoplastic material. The fabric-based reinforcing sheet is wound about a mandrel to form a plurality of layers having a cross-sectional shape that corresponds to the mandrel. The fabric-based reinforcing sheet includes a plurality of fiber bundles, which may have a bidirectional orientation or configuration. A polymerized thermoplastic material is disposed within each layer of the fabric-based reinforcing sheet. The polymerized thermoplastic material bonds each layer of the fabric-based reinforcing sheet to an adjacent layer.

A thermoplastic product includes a fabric-based reinforcing sheet and a polymerized thermoplastic material. The fabric-based reinforcing sheet is wound about a mandrel to form a plurality of layers having a cross-sectional shape that corresponds to the mandrel. The fabric-based reinforcing sheet includes a plurality of fiber bundles, which may have a bidirectional orientation or configuration. A polymerized thermoplastic material is disposed within each layer of the fabric-based reinforcing sheet. The polymerized thermoplastic material bonds each layer of the fabric-based reinforcing sheet to an adjacent layer.

The invention relates to methods of bonding and a conductively bonded joint, provided by high loadings of conductively coated nano scale particulate fillers in a conductive adhesive in combination with a conductive intermediary structure, more particularly to a lightning strike resilient bonded joint between fibre reinforced polymer composites. A method of joining a first fibre reinforced polymer composite surface and a second fibre reinforced polymer composite surface, comprising the steps of providing a conductive intermediary structure between said first and second surfaces, filling the void between said surfaces and enveloping said intermediary structure with a conductive adhesive, curing the conductive adhesive to form a bonded first and second surface. A conductive adhesive comprising a curable binder and a high aspect ratio nanoscale carbon particulate filler present in the range of from 0.1 to 40% wt, wherein said particulate filler comprises a metal coating.

A method of forming a vacuum insulated structure includes providing a multi-layer sheet of material comprising at least one layer of barrier material that is disposed between first and second outer layers. The barrier material and the first and second outer layers comprise thermoplastic polymers. The multi-layer sheet of material is thermoformed to form a non-planar first component. The first component is at least partially coated utilizing a plasma polymerization process or a physical vapor deposition process to improve the barrier properties of the first component. The method further includes securing a second component to the first component to form an interior space therebetween. Porous filler material is positioned in the interior space, and a vacuum is formed in the interior space.

An assembly for use on an aircraft wing having an aircraft skin and a fuel tank, the assembly comprising a metal access door for accessing the fuel tank, a metal retainer ring for engaging the wing and the access door. Fasteners removably couple the access door to the retainer ring. A lip, which may be on the wing surface, is configured to receive a perimeter of the access door when the access door is coupled to the retainer ring. A polyurethane elastomeric gel gasket having a metallic skeleton is configured to lay between the access door and a lip of the metal wing surface. Under compression, the polyurethane will deform and squeeze out the edges and flatten so as to provide metal-to-metal contact between the access door and the lip.

A method for manufacturing a reel includes molding a reel configuration component that is made of resin and includes a reel hub with an outer peripheral face for winding a recording tape onto, after the molding and prior to the reel configuration component cooling and shrinking, embedding a reinforcement ring into the reel hub, and after the embedding, cooling and shrinking the reel configuration component and fixing the reinforcement ring to the reel hub.

A method for simple and economical positioning of two work pieces with one another wherein the pieces are welded using induction heating to melt a polymer in a composite wherein air can be blown on the surface to limit the welding to an area close to the mating surface of the work pieces and to prevent melting of the outer surface which would deteriorate the quality of the outer surface.

A method for simple and economical positioning of two work pieces with one another wherein the pieces are welded using induction heating to melt a polymer in a composite wherein air can be blown on the surface to limit the welding to an area close to the mating surface of the work pieces and to prevent melting of the outer surface which would deteriorate the quality of the outer surface.

The application describes methods of making composite bodies including fibre-reinforced composite material with carbon fibre reinforcement and also a metal-containing portion (4). The metal-containing portion (4) is formed by laying up metal reinforcement elements, such as tapes of titanium alloy, among the carbon fibre reinforcement tapes which make up the composite body. The proportion of metal reinforcement may increase progressively towards the surface and/or towards an edge (14) of the composite body. In an example, metal leading and trailing edges (14,15) of a fan blade (1) are integrally formed in this way.