A method of bonding a first object to a second object, including the steps of: providing a profile body having a first profile body portion; providing the first object, wherein the first object has thermoplastic material; providing the second object, wherein the profile body is separate from and attachable to the second object or wherein the second object includes the profile body; embedding the profile body in the first object such that the first profile body portion is within the thermoplastic material of the first object. Embedding the profile body in the first object is caused by mechanical energy impinging on the first object and/or on the second object while the first object and the second object are pressed against each other.

A profile body of a not liquefiable material is used as a connecting element between a first object and a second object. The profile body may especially be metallic and/or may be bendable. The profile body, in contrast to a conventional wire, however, has a shape defining a first and a second undercut. The method includes embedding the profile body in the second object so that the second undercut is within material of the second object, and embedding the profile body within material of the first object so that the first undercut is within the first object, and wherein at least embedding of the profile body in the first object is caused by mechanical energy impinging on the first object and/or on the second object while the first object and the second object are pressed against each other.

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.

Systems and methods are provided for blade-and-slot panel affixation. One embodiment is a method. The method includes cutting a first slot into a first composite panel that includes a core between two facesheets. The first slot penetrates through the core of the first composite panel. The method also includes cutting a second slot into a second composite panel that includes a core between two facesheets. The second slot penetrates through a facesheet of the second composite panel as well as the core of the second composite panel. The method further includes inserting a blade into the first slot, and inserting the blade into the second slot.

A method or apparatus for joining a first component to a second component with an amalgamation plate includes heating the first component, the second component, the amalgamation plate, or combinations thereof, with either a joining tool or a heating element. The components are attached to the amalgamation plate with the joining tool, such that the first component, amalgamation plate, and the second component are fixedly attached to one another, and the amalgamation plate may be substantially surrounded by the first component and the second component, such that it is hidden from exposure. Portions of the amalgamation plate may be embedded into the components via rotation and/or linear force. A portion of the amalgamation plate may be recessed within the joining tool or an anvil before attaching the amalgamation plate to the either component.

A control rod for incorporation into a composite assembly with at least a first composite preform, a second composite preform, and a cured resin includes a shaft defining an axis, wherein the shaft is disposable within an aperture in the composite assembly, and a plurality of threads disposed on at least a portion of the shaft. The shaft is made from, among other materials, a thermoplastic material. The threads define a thread pitch that encompasses more than one individual fiber layer forming at least one of the first composite layer and the second composite layer.

A process for joining fiber composite materials using self-piercing rivets. The process includes contacting first and second panels. The second panel is a fiber composite material. The process further includes elevating a temperature of only a fastening portion of the second panel. The process also includes placing the first and second panels on a die and joining the first and second panels with one or more rivets while the fastening portion is at an elevated temperature.

A method for inserting an insert into a hole in a composite material made from a plurality of carbon fiber layers suspended in a resin material includes lowering a temperature of the insert to a reduced temperature at which a coefficient of thermal expansion of a material of the insert causes the insert to contract to a first perimeter, inserting the insert at the reduced temperature into the hole, and permitting the temperature of the insert to increase from the reduced temperature to an operational temperature. At the operational temperature, the insert expands to a second perimeter so that the insert is retained within the composite material due to an interference between the insert and the composite material. The interference transfers a structural load from the insert to the composite material and results in damage to the composite material if the insert is dislodged at the operational temperature.

A foam structural material includes a first core material and a reinforcing material. The first core material has a first portion of a linear groove part formed along an edge of the first core material. The reinforcing material has a first side fitted to the first portion of the linear groove part. The first portion of the linear groove part includes a first engagement plane. The first engagement plane is engaged with the reinforcing material and has one or a plurality of projections formed thereon.

A method of mechanically securing a first object including a thermoplastic material in a solid state to a second object with a generally flat sheet portion, with a perforation of the sheet portion, and with the sheet portion having an edge along the perforation is provided, wherein the first object is positioned relative to the second object so that the edge is in contact with the thermoplastic material and wherein mechanical vibration energy is coupled into the assembly including the first and second objects until a flow portion of the thermoplastic material due to friction heat generated between the edge and the thermoplastic material becomes flowable and flows around the edge to at least partially embed the edge in the thermoplastic material. After the mechanical vibration stops, the thermoplastic material is caused to re-solidify, whereby the re-solidified thermoplastic material at least partially embedding the edge anchors the first object in the second object.