A thermoplastic composite structure is produced by consolidating and forming a composite preform to a desired shape. The preform comprises plies of a high melt temperature thermoplastic prepreg that are tacked together by a low melt temperature thermoplastic adhering the plies together in fixed registration.

A mechanical part configured to be placed under torque. The mechanical part includes an inner tube having, a corrugated web, and an outer shell. The inner tube has an outer tube circumference, a tube axial direction, and a tube length. The corrugated web has a plurality of peaks and a plurality of troughs, a height measured as a difference between one of the peaks and one of the troughs, and a web length perpendicular to the height and in the tube axial direction. The outer shell has an inner shell circumference, an outer shell circumference, and a shell length. The plurality of troughs is affixed to the outer circumference of the inner tube. The plurality of peaks is affixed to the inner shell circumference of the outer shell. The web length is aligned with the tube length and the shell length.

A mechanical part configured to be placed under torque. The mechanical part includes an inner tube having, a corrugated web, and an outer shell. The inner tube has an outer tube circumference, a tube axial direction, and a tube length. The corrugated web has a plurality of peaks and a plurality of troughs, a height measured as a difference between one of the peaks and one of the troughs, and a web length perpendicular to the height and in the tube axial direction. The outer shell has an inner shell circumference, an outer shell circumference, and a shell length. The plurality of troughs is affixed to the outer circumference of the inner tube. The plurality of peaks is affixed to the inner shell circumference of the outer shell. The web length is aligned with the tube length and the shell length.

A long frame is provided with: a plurality of frame members that have a longitudinal direction and a short direction, have a first flange part folded along a folding line extending along the longitudinal direction, and are arranged close to an inner peripheral surface of a surface plate along an array direction; and a plurality of first connecting parts that connect each of the plurality of first flange parts to the surface plate. The frame is further provided with at least one of a second connecting part that connects second flange parts to each other and a third connecting part that joins together end surfaces of a pair of frame members arranged adjacent to each other in the array direction to connect the pair of frame member arranged adjacent to each other.

A protective guard for a hand, finger or thumb includes a first thermoplastic layer heat welded to second thermoplastic layer. The second thermoplastic layer has a thickness that is greater than the thickness of the first thermoplastic layer.

A multilayer sealed skin, in particular for an inflatable structure and that includes a first polymer film, a reinforcing fabric disposed on the first polymer film and a second polymer film disposed on the reinforcing fabric and adhered by means of an adhesive to the first polymer film through cavities in the reinforcing fabric. The skin can be applied to the production of an inflatable structural element such as an inflatable beam for which the skin forms an outer wall of the structural element and for which the first film of the skin forms an inner face of the outer wall of the structural element, and the second film forms an outer face of the wall.

A method of making a brush includes providing a plurality of first filaments, each having a first end and a second end; bringing the plurality of first filaments into a first predetermined shape such that the first ends are arranged side by side on a common contour; fixedly connecting the first ends so that a first pre-tuft having the first predetermined shape and a connected first end is formed; bringing a second tuft element having a first end and a second end together with the first pre-tuft into a second predetermined shape such that the first end of the second tuft element and the connected first end of the first pre-tuft are arranged side by side on a common contour; fixedly connecting the connected first end of the first pre-tuft and the first end of the at least second tuft element so that a final tuft having the second predetermined shape and a connected end is formed; and attaching the final tuft to a brush body by overmolding the final tuft's connected end with a plastic material.

A method of making a brush includes providing a plurality of first filaments, each having a first end and a second end; bringing the plurality of first filaments into a first predetermined shape such that the first ends are arranged side by side on a common contour; fixedly connecting the first ends so that a first pre-tuft having the first predetermined shape and a connected first end is formed; bringing a second tuft element having a first end and a second end together with the first pre-tuft into a second predetermined shape such that the first end of the second tuft element and the connected first end of the first pre-tuft are arranged side by side on a common contour; fixedly connecting the connected first end of the first pre-tuft and the first end of the at least second tuft element so that a final tuft having the second predetermined shape and a connected end is formed; and attaching the final tuft to a brush body by overmolding the final tuft's connected end with a plastic material.

Various embodiments disclosed relate to a sealed storage tank. The sealed storage tank includes a first polymeric layer. The sealed storage tank further includes a second polymeric layer continuously welded to the first polymeric layer to form the sealed storage tank. The sealed storage tank further includes an optional vent formed in the first polymeric layer or the second polymeric layer. The sealed storage tank can be configured to hold at least 13,000 liters of liquid.

A method for bonding composite substrates includes coupling a first co-cure prepreg layer having a first off-set amine to epoxide molar ratio onto a surface of a first composite substrate and coupling a second co-cure prepreg layer having a second off-set amine to epoxide molar ratio onto a surface of a second composite substrate. The first and second composite substrates are cured to the first and second co-cure prepreg layers, respectively, using a first cure cycle (including B-stage and cure temperatures) to form a first and a second co-cure prepreg layer portion. The method further includes coupling the first co-cure prepreg layer portion to the second co-cure prepreg layer portion and applying a second cure cycle to cure the first co-cure prepreg layer portion of the first composite substrate to the second co-cure prepreg layer portion of the second composite substrate to form a monolithic covalently bonded composite structure.