Integrated pultruded composite profiles such as rotor wings and blades for electric vertical take-off and landing aircraft, light helicopters, wind turbines, and other rotor wing applications and integrated design and processing methods for making same are disclosed. The present invention provides a plurality of web ribs for stiffening and supporting an outer skin which can comprise fabric plies, a metallic skin, or a thermoplastic composite skin. A process and method to continuously pultrude integrated composite airfoil profile with variable aerodynamic twist is also disclosed. Utilization of a stranded metallic wire rope that enables the leading edge weight to be continuously in-situ fed into the pultrusion process and effectively retained in the pultruded product is also disclosed. Utilization of fiber reinforcement impregnated with matrix resin that is loaded with high density powder for the leading edge weight is also disclosed.

A method for joining two objects by anchoring an insert portion provided on a first object in an opening provided on a second object. The anchorage is achieved by liquefaction of a thermoplastic material and interpenetration of the liquefied material and a penetrable material, the two materials being arranged on opposite surfaces of the insert portion and the wall of the opening. During the step of inserting the insert portion in the opening and/or during anchorage a clamping force is applied to opposing surfaces of the second object to prevent the second object from cracking or bulging.

A method for joining two objects by anchoring an insert portion provided on a first object in an opening provided on a second object. The anchorage is achieved by liquefaction of a thermoplastic material and interpenetration of the liquefied material and a penetrable material, the two materials being arranged on opposite surfaces of the insert portion and the wall of the opening. During the step of inserting the insert portion in the opening and/or during anchorage a clamping force is applied to opposing surfaces of the second object to prevent the second object from cracking or bulging.

A method for plasma treating a surface of a first substrate is disclosed. The method may comprise generating a plasma flume using a plasma treatment device having a nozzle. The plasma flume may emanate through a flume aperture of the nozzle at an emanation angle of about 5 degrees or less. The emanation angle may be defined as an angle between a central axis of the nozzle and a central axis of the flume aperture. The method may further comprise plasma treating the surface of the first substrate with the plasma flume by scanning the plasma flume over the surface of the first substrate. The first substrate may be one of a consolidated thermoplastic material and a cured thermoset material.

A method for plasma treating a surface of a first substrate is disclosed. The method may comprise generating a plasma flume using a plasma treatment device having a nozzle. The plasma flume may emanate through a flume aperture of the nozzle at an emanation angle of about 5 degrees or less. The emanation angle may be defined as an angle between a central axis of the nozzle and a central axis of the flume aperture. The method may further comprise plasma treating the surface of the first substrate with the plasma flume by scanning the plasma flume over the surface of the first substrate. The first substrate may be one of a consolidated thermoplastic material and a cured thermoset material.

A golf club head includes a striking face, a crown and a sole. The crown and/or the sole includes an FRP member formed by a fiber reinforced plastic that contains a fiber and a matrix resin. The FRP member has an average flexural modulus of greater than or equal to 25 GPa. The fiber may contain a carbon fiber. The carbon fiber may have a tensile elastic modulus of greater than or equal to 300 GPa. The fiber may contain a metallic fiber. The FRP member may have a resin content of less than or equal to 40% by weight. The matrix resin may have a glass transition temperature of higher than or equal to 150 C.

A golf club head includes a striking face, a crown and a sole. The crown and/or the sole includes an FRP member formed by a fiber reinforced plastic that contains a fiber and a matrix resin. The FRP member has an average flexural modulus of greater than or equal to 25 GPa. The fiber may contain a carbon fiber. The carbon fiber may have a tensile elastic modulus of greater than or equal to 300 GPa. The fiber may contain a metallic fiber. The FRP member may have a resin content of less than or equal to 40% by weight. The matrix resin may have a glass transition temperature of higher than or equal to 150 C.

A preform-charge fixture creates a preform charge, which is a partially consolidated assemblage of preforms that can be efficiently transferred to a mold to create a finished part in a molding process, such as compression molding. In the illustrative embodiment, the preform-charge fixture includes peripheral cleats that are movable towards a central cleat to create a small gap therebetween that receives and constrains preforms in a desired position. The fixture also includes clamps, which are operable to engage an uppermost layer of preforms in the gap and apply a slight amount of downward pressure thereto to assure that the preforms are properly seated. The fixture also accommodates an energy source that heats the preforms so that, in conjunction with downforce applied by the clamps and/or gravity, the preforms can be tacked together, forming the preform charge.

A preform-charge fixture creates a preform charge, which is a partially consolidated assemblage of preforms that can be efficiently transferred to a mold to create a finished part in a molding process, such as compression molding. In the illustrative embodiment, the preform-charge fixture includes peripheral cleats that are movable towards a central cleat to create a small gap therebetween that receives and constrains preforms in a desired position. The fixture also includes clamps, which are operable to engage an uppermost layer of preforms in the gap and apply a slight amount of downward pressure thereto to assure that the preforms are properly seated. The fixture also accommodates an energy source that heats the preforms so that, in conjunction with downforce applied by the clamps and/or gravity, the preforms can be tacked together, forming the preform charge.

A fiber-reinforced laminate including at least a layer of woven fibers and a layer of short fiber-containing resin composition, wherein the short fiber-containing resin composition is present in gaps formed by crossing fiber bundles composing the woven fibers. Also disclosed is a method for producing the laminate.