The device for welding thermoplastic parts includes a matrix for positioning the parts to be assembled, the matrix including an amagnetic insulating insert that defines joining zones in which the welds must be produced, a bladder defining a sealed volume and means for producing a partial vacuum in the sealed volume, and means for moving a magnetic induction head to near the joining zones and without making contact with the bladder. The welding process includes positioning at least one first part, then of placing metal inserts on areas of the first part corresponding to the joining zones that must be welded, and then positioning at least one second part. A bladder is put in place covering the parts and a partial vacuum is created in the volume defined by the bladder. The magnetic induction head is moved to produce the weld bead without contact while the partial vacuum is maintained.

A method attaches a liquid-repellent filter to an air vent of a resin molded article accommodating a component/electronic part. A thermal processing tip and a thermally welding tip and a molded article are provided. The thermal processing tip (22) forms a filter attachment surface (14) at the inlet or outlet of an air vent (16) in a thermoplastic resin molded article (13). A filter fixing rib (15) is formed around the attachment surface. The porous filter (18) is dropped onto the filter attachment surface, and a thermal welding tip (2) is used to melt the filter fixing rib such that the melted resin flows onto and covers a circumferential edge portion of the filter, penetrating the body of the filter. The melted resin penetrating the filter 18 and covering the circumferential edge portion of the filter are cooled to solid, whereby the filter is fixed to the filter attachment surface.

A method of repairing a thermoplastic panel having a damaged portion therein that includes the steps of obtaining a patch member made of a thermoplastic material, positioning the patch member over the damaged portion, positioning the panel and patch member on a heat sink tool, using a hot forming tool to soften the panel and the patch member such that the material of the panel and the material of the patch member are welded together, and cooling the panel and patch member to integrally bond the patch member to the panel, thereby forming a panel and patch assembly.

A method of making a panel assembly that includes forming a thermoplastic panel, placing a thermoset portion into a pocket in a mold, placing an attachment member into the pocket in the mold, positioning the thermoplastic panel in the mold, cooling the thermoplastic panel while heating the thermoset portion to flow at least a portion of the thermoset portion into openings defined in the thermoplastic panel, and cooling the panel assembly so that the thermoset portion hardens, thereby securing the attachment member to the thermoplastic panel.

A heatsink, a method of manufacturing the heatsink, and an induction welding apparatus including the heatsink. The heatsink includes a carrier sheet and a plurality of tiles. The carrier sheet comprises an electrically non-conductive material and has a contoured profile. The plurality of tiles comprises a thermally conductive and electrically non-conductive material. Each tile of the plurality of tiles has a bonding surface bonded to the carrier sheet and a contact surface opposite the bonding surface. The contact surface is configured to contact a structure to be induction welded.

An induction welding coil includes a spine having a planar body with opposing ends, and a pair of prongs extending perpendicularly from the opposing ends of the spine. Each of the prongs has a planar body, wherein the spine and the pair of prongs are formed from a ferrite material to define a ferrite core. The induction welding coil further includes a coil wire having a plurality of winding that surround the planar body of the spine.

A heat sink for use in electromagnetic welding of molded parts includes reinforcing fibers embedded in a matrix material, where substantially all of the reinforcing fibers are oriented unidirectionally in a fiber direction, where the reinforcing fibers have a thermal conductivity at room temperature from 100-1000 W/m. K and an electrical resistivity at room temperature from 0.5-10.m, and where the matrix material comprises a high temperature resistant material, optionally a thermosetting resin, having a glass transition temperature Tg above 350 C. The heat sink is used in a method of connecting surfaces of a first molded part and a second molded part by electromagnetic welding. Cooling of the outer surface of the first molded part is provided by the heat sink in direct contact with the outer surface.

An apparatus and method for operating a staking assembly includes a housing defining a machining passage having a longitudinal axis, an actuator rod disposed for axial movement along the longitudinal axis in the machining passage, having a first end configured to connect to a linear-reciprocating source of movement and a second end having a tool configured to deform a boss, and an air source configured to selectively provide a source of heated air.

A method and a connecting element for joining two components, at least one of which is made of a fiber-reinforced composite, are proposed.

The objective of the present invention is to provide a vehicle door trim bonding device capable of quickly bonding sub-trims. In order to achieve the objective, the present invention provides a vehicle door trim bonding device for coupling a first sub-trim in which a projection is formed and which is made of a thermoplastic resin material, and a second sub-trim in which a receiving hole for receiving the projection of the first sub-trim is formed and which is made of a thermoplastic resin material, the device comprising: a heat supply unit for melting a part of the protrusion with radiation heat; and a molding part for compression-molding the molten protrusion.