A method for joining a device to an object with the aid of a combination of ultrasonic vibration energy and induction heating, wherein the device includes a portion of a thermoplastic polymer and a susceptor additive wherein this portion is at least partly liquefied or plasticized through the ultrasonic vibration energy in combination with the induction heating and wherein the joining includes establishing a connection between the device and the object which connection is at least one of a positive fit connection, a weld, a press fit connection, and an adhesive connection. The induction heating is applied for rendering the device portion suitable for absorption of ultrasonic vibration energy than other device portions by raising its temperature above the glass transition temperature of the polymer. The ultrasonic vibration energy is used for liquefying or at least plasticizing the thermoplastic polymer of the named device portion.

A process for laminating a material layer to a support including: providing the support, applying the material layer to the support, a heat-activatable adhesive being applied to s side of the material layer facing the dimensionally stable support and/or to the side of the dimensionally stable support facing the material layer, pressing the flexible material layer and the dimensionally stable support together by means of a lower dimensionally stable mold half and an upper dimensionally stable mold half, irradiating the mold halves, the support and the material layer with electromagnetic radiation, in particular with microwave radiation, high-frequency radiation or induction radiation, whereby the adhesive is activated directly or indirectly.

The present disclosure is directed to methods for joining rotor blade components using thermoplastic welding. The method includes arranging a first thermoplastic component and a second thermoplastic component together at an interface, determining a size of a tolerance gap between the first and second components at the interface, placing a thermoplastic insert between the first and second components at the interface, the insert being larger than the tolerance gap, heating the insert and the first and second components such that the insert begins to flow so as to fill the tolerance gap between the first and second components, applying pressure to the interface such that the insert and the first and second blade components remain substantially in direct contact with each other at the interface, and welding the insert and the first and second components together at the interface, wherein the heat and the applied pressure between the insert and the first and second components at the interface maintain the insert and the first and second substantially in direct contact at the interface during welding.

A composite fibrous susceptor for use in induction welding is described, along with methods of its construction and use. The composite fibrous susceptor can include a magnetically susceptible continuous fiber in conjunction with a thermoplastic polymer. The composite fibrous susceptor can be deposited according to an additive manufacturing process on a surface to be bonded according to an induction welding process.

Provided is an adhesive that can provide quick bonding between thermoplastic resins and excellent bond strength, a structure having adhesion provided by the adhesive, and an adhesion method using the adhesive. The adhesive bonds a first member (11) containing a thermoplastic resin or a carbon fiber reinforced thermoplastic resin and a second member (12) containing the thermoplastic resin or the carbon fiber reinforced thermoplastic resin. The adhesive includes a thermoplastic resin as a main component containing a metal nano material that absorbs electromagnetic waves and generates heat.

A composite fibrous susceptor for use in induction welding is described, along with methods of its construction and use. The composite fibrous susceptor can include a magnetically susceptible continuous fiber in conjunction with a thermoplastic polymer. The composite fibrous susceptor can be deposited according to an additive manufacturing process on a surface to be bonded according to an induction welding process.

A stringer and corresponding method is provided having a runout design that softens the stringer. According to one aspect, the stringer includes a base flange, a web, and a noodle. The noodle includes a unidirectional fiber top portion and a stacked laminate bottom portion coupled to the top portion. The bottom portion includes a number of stacks, each stack including three plies having three corresponding fiber orientations within an acreage region of the stringer. In a transition region of the stringer, the stacked laminate bottom portion includes a number of stacks, each stack including the first and third plies of the acreage region. According to another aspect, the base flange is softened by dropping plies within the transition region. Yet another aspect includes trimming the web down to the noodle, while trimming through the noodle according to a trim radius to a height proximate the base flange.

A stringer and corresponding method is provided having a runout design that softens the stringer. According to one aspect, the stringer includes a base flange, a web, and a noodle. The noodle includes a unidirectional fiber top portion and a stacked laminate bottom portion coupled to the top portion. The bottom portion includes a number of stacks, each stack including three plies having three corresponding fiber orientations within an acreage region of the stringer. In a transition region of the stringer, the stacked laminate bottom portion includes a number of stacks, each stack including the first and third plies of the acreage region. According to another aspect, the base flange is softened by dropping plies within the transition region. Yet another aspect includes trimming the web down to the noodle, while trimming through the noodle according to a trim radius to a height proximate the base flange.

A composite laminate is made by providing at least a first composite ply and a second composite ply, each having longitudinally oriented fibers in a thermoplastic matrix. The second composite ply is disposed on, and in transverse relation to, the first composite ply. Preferably, the second ply is disposed at 90 relative to the first ply. An article can be manufactured by providing a core material and applying a reinforcing material to a portion of the core material. The reinforcing material is a reinforcing composite ply or a composite laminate as described herein. Optionally, the core material is a prepreg that may be a composite laminate.

A method for joining sections of at least two components, particularly vehicle components, includes mutually connecting the joining sections exclusively by the use of a fibrous duroplastic molding compound.