An apparatus includes a first thermoset layer that includes a first fibrous material embedded in a first thermoset matrix. The apparatus also includes a second thermoset layer that includes a second fibrous material embedded in a second thermoset matrix. The second thermoset layer is coupled to the first thermoset layer to form a joint. Further, a gap is defined between the first thermoset layer and the second thermoset layer. The apparatus also includes a thermoplastic filler that is made from a thermoplastic material. The thermoplastic filler is positioned within the gap.

A bonded structure includes a first fiber part (12) and a second fiber part (14) arranged between a first member (10) and a second member (20). The first fiber part (12) and the second fiber part (14) are bonded so as to connect the first member (10) and the second member (20) to each other. The first fiber part (12) and the second fiber part (14) are arranged so that the fibers constituting the first fiber part (12) and the second fiber part (14) are oriented in a direction from the first member (10) toward the second member (20).

A thin ribbon spirally wound polymer conduit and method of forming, wherein a helical reinforcing bead is interposed adjacent overlapping layers of ribbon. Further, a method of continuously forming spirally wound conduit wherein a sacrificial layer, preferably having a different base polymer to that of the conduit, is first applied to the former before the conduit is formed overtop.

A method of reducing residual stress in a composite assembly may include assembling a first composite part to a second composite part to form a detail assembly. The first and second composite part may each have a flange and a web connected by a bend radius. The webs may be arranged back-to-back. The detail assembly may be cured on a compensated cure tool compensated for cure shrinkage spring-in predicted to occur in the first and second composite part. The method may include allowing the first and second composite part to spring in from cure shrinkage, and assembling the detail assembly to an uncured third composite. The method may also include co-bonding the detail assembly to the third composite part on an assembly cure tool to form a composite assembly having reduced cure shrinkage residual stress in the bend radii of the first and second composite part.

A machine and method for making an inflatable product is disclosed. The inflatable product has an upper layer and a lower layer. The machine having a presser, a welder press frame, an upper flat plate secured to the presser, and a lower flat plate secured to the welder press frame. Each flat plate has a plurality of slide rests, each slide rest having a plurality of detachable plates positioned along the slide rest. A lower layer of material is placed on top of the lower flat plate and on top of the plurality of detachable plates on the lower flat plate. A plurality of die assemblies is positioned on top of the lower layer of material in a manner where each die assembly is aligned with a corresponding slide rest. Then, an upper layer of material is placed on top of the die assemblies and below the upper flat plate. The upper flat plate is pressed on top of the upper layer of material to perform heat welding.

A thermoplastic composite structure is produced by extruding a bead of composite material to a desired cross sectional shape. An extruder extrudes the polymer bead containing reinforcing fibers, using a low compression first extruder stage where the polymer is mixed and de-gassed, and a high compression second stage where the polymer is consolidated and extruded. The cross sectional profile of the polymer bead may be altered using a variable extruder gate.

A thermoplastic composite structure is produced by extruding a bead of composite material to a desired cross sectional shape. An extruder extrudes the polymer bead containing reinforcing fibers, using a low compression first extruder stage where the polymer is mixed and de-gassed, and a high compression second stage where the polymer is consolidated and extruded. The cross sectional profile of the polymer bead may be altered using a variable extruder gate.

A machine and method for making an inflatable product is disclosed. The inflatable product has an upper layer and a lower layer. The machine having a presser, a welder press frame, an upper flat plate secured to the presser, and a lower flat plate secured to the welder press frame. Each flat plate has a plurality of slide rests, each slide rest having a plurality of detachable plates positioned along the slide rest. A lower layer of material is placed on top of the lower flat plate and on top of the plurality of detachable plates on the lower flat plate. A plurality of die assemblies is positioned on top of the lower layer of material in a manner where each die assembly is aligned with a corresponding slide rest. Then, an upper layer of material is placed on top of the die assemblies and below the upper flat plate. The upper flat plate is pressed on top of the upper layer of material to perform heat welding.

A limb for a breathing circuit manufactured from very thin walled polymer materials has an elongate axial reinforcing spine lying freely inside the conduit and fixed to each end connector. The spine is laterally compliant but axially stiff. The spine provides resistance to tensile and compressive loads on the conduit, including that induced by prevailing internal pressures.

A composite radius filler material is provided. The composite radius filler includes a resin, a first group of fibers dispersed within the resin, and a second group of fibers dispersed within the resin. The first group of fibers has a first length configured to facilitate orientation in a longitudinal direction. The second group of fibers has a second length that is shorter than the first length, with the second group of fibers configured to facilitate random orientation in a transverse direction.