A system and method for welding thermoplastic components by positioning and moving a heated plate between the components to melt their respective faying surfaces, and as the plate moves, pressing the components together so that the melted faying surfaces bond together as they cool and re-solidify, thereby creating a composite structure. The plate has a heated portion which is positioned between and heated to melt a portion of the first and second faying surfaces. A manipulator mechanism moves the plate along an interface from between the portion to between a series of subsequent portions of the first and second faying surfaces, thereby welding the thermoplastic components along the entire interface to create the composite structure. The heated portion may contact the faying surfaces and melt them through conduction, or may be suspended between them and melt them through radiation and convection.

Apparatus and associated methods relate to an enhanced auxetic composite material (EACM) of a base thermoplastic elastomer (TPE) and/or a thermoset material combined with an auxetic material, the composite formed with a molding process, where the base material is injected or dripped into or injected, dripped or formed around the auxetic material, the composite material providing higher impact performance than the individual materials. In an illustrative example, combining various energy absorbing materials with auxetic materials may further enhance impact performance. In some examples, TPE material injected into auxetic structures may fill internal voids. In some examples, the auxetic material may be suspended within the TPE material and be encapsulated around the auxetic material form. Auxetic materials may take various forms, for example, sheets, 3-D structures, and particles, each providing unique benefits. Various embodiments included within various personal protection articles may advantageously provide long life and enhance impact resistance.

Disclosed embodiments provide automated fiber placement techniques for fabrication of parts made from composite materials. A peening system with multiple pins provides compaction over irregular surfaces, providing superior performance as compared with traditional compaction rollers. The apparatus that carries out the techniques include a tape dispensing system, a heating system, a peening system, a processor and a memory coupled to the processor. The memory contains instructions that when executed by the processor perform the steps of: dispensing a first ply of thermoplastic composite tape over a mandrel; dispensing a second ply of thermoplastic composite tape on the first ply; and peening the second ply onto the first ply, such that the second ply is bonded to the first ply.

A system and method for welding thermoplastic components by positioning and moving a heated plate between the components to melt their respective faying surfaces, and as the plate moves, pressing the components together so that the melted faying surfaces bond together as they cool and re-solidify, thereby creating a composite structure. The plate has a heated portion which is positioned between and heated to melt a portion of the first and second faying surfaces. A manipulator mechanism moves the plate along an interface from between the portion to between a series of subsequent portions of the first and second faying surfaces, thereby welding the thermoplastic components along the entire interface to create the composite structure. The heated portion may contact the faying surfaces and melt them through conduction, or may be suspended between them and melt them through radiation and convection.

The application relates to a nonwoven composite containing a plurality of solid regions and a plurality of porous regions. The solid and porous regions form a repeating pattern on the surface of the composite. The solid regions contain a solid region nonwoven layer, an optional solid region polymer-fiber infused layer, and a solid region cap layer. The solid region nonwoven layer contains a plurality of first staple fibers and less than about 5% by volume of a first polymer. The solid region cap layer contains the first polymer and less than about 5% by volume of the first staple fibers. The porous regions contain a porous region nonwoven layer and a porous region polymer-fiber infused layer. The porous region nonwoven layer contains a plurality of the first staple fibers and less than about 5% by volume of a first polymer. The porous region polymer-fiber infused layer contains a plurality of pores.

A method for fabricating wetsuit garment including wetsuits, boots and gloves for water sports uses, comprising preparation of at least a high-elasticity joining member made of hot melt adhesive, and joining at least two interconnected panels of rubber foam or sponge by the high-elasticity joining member to cover and seal the seam between the two interconnected panels for firmly bonding the two interconnected panels for making a strong, elastic and flexible wetsuit garment.

Resin-molded articles, to which such advantages as strength, rigidness and light weight are secured thanks to kneading with fibers, and which has excellent surface characteristics such as smoothness of the surface and beauty in the appearance, and resistance against weather, ultraviolet rays and light are provided.

The resin-molded article 10 is structured by sticking a resin surface skin member 3 provided with an adhering layer 2 to a molded fibrous base member 1 comprising any of carbon fibers, glass fibers and the complex thereof, and the resin-molded article is manufactured according to the following steps, specifically a step of placing a molded member comprising mixture of fibers and resin on a tray 23, a step to arrange a resin surface skin member provided with an adhering layer onto the molded member such that the adhering layer of the resin surface skin member is directed downward, a step to render the surroundings of the molded member and the resin surface skin member in a negatively-pressurized condition and to concurrently heat the resin surface skin member to raise the tray so that the molded member is closely contacted to the softened resin surface skin member, a step to render the upper part of the tray in a pressurized condition, a step to release the pressure applied to surrounding of the tray and a step to remove the molded base covered with the resin surface skin member.

Resin-molded articles, to which such advantages as strength, rigidness and light weight are secured thanks to kneading with fibers, and which has excellent surface characteristics such as smoothness of the surface and beauty in the appearance, and resistance against weather, ultraviolet rays and light are provided.

The resin-molded article 10 is structured by sticking a resin surface skin member 3 provided with an adhering layer 2 to a molded fibrous base member 1 comprising any of carbon fibers, glass fibers and the complex thereof, and the resin-molded article is manufactured according to the following steps, specifically a step of placing a molded member comprising mixture of fibers and resin on a tray 23, a step to arrange a resin surface skin member provided with an adhering layer onto the molded member such that the adhering layer of the resin surface skin member is directed downward, a step to render the surroundings of the molded member and the resin surface skin member in a negatively-pressurized condition and to concurrently heat the resin surface skin member to raise the tray so that the molded member is closely contacted to the softened resin surface skin member, a step to render the upper part of the tray in a pressurized condition, a step to release the pressure applied to surrounding of the tray and a step to remove the molded base covered with the resin surface skin member.

Provided are a manufacturing device and a manufacturing method, for a one-side metal-clad laminated sheet (E), enabling: manufacturing a one-side metal-clad laminated sheet (E) without a thermoplastic resin layer (B) surface, on the side on which metal foil (D) is not laminated, being fused with a metal roller or a protective film even if the thermoplastic resin layers (B) are provided on both sides of a heat-resisting film (A) that is a core layer; and inexpensively and easily obtaining a one-side metal laminated sheet in which warpage is inhibited from occurring.

Provided are a manufacturing device and a manufacturing method, for a one-side metal-clad laminated sheet (E), enabling: manufacturing a one-side metal-clad laminated sheet (E) without a thermoplastic resin layer (B) surface, on the side on which metal foil (D) is not laminated, being fused with a metal roller or a protective film even if the thermoplastic resin layers (B) are provided on both sides of a heat-resisting film (A) that is a core layer; and inexpensively and easily obtaining a one-side metal laminated sheet in which warpage is inhibited from occurring.