A microwave heating device includes a variable frequency microwave power supply, a waveguide launcher, and a fixture to contain a material to be heated, with the fixture located directly adjacent to the end of the launcher. All heating occurs in the near-field region, i.e., no cavity modes or standing waves are established within the fixture. This condition may be insured by keeping the thickness of the fixture or workpiece under one wavelength (at all microwave frequencies being used). The launcher is preferably a horn configured to spread the microwave power laterally over a selected area while maintaining a single propagating mode. The invention may be used to enhance catalytic reactions for research and other purposes. Alternatively, the invention may be configured to perform spot curing or repair operations involving adhesives and composites.

A joining method and assembly for an aircraft. To improve the characteristics or permit hitherto impossible connections between thermoplastic and thermoset components, a multi-material joining method is disclosed in which a thermoplastic connecting region is formed on the thermoplastic component. The connecting region is connected to the thermoset component by interdiffusion. For this purpose, the uncured second component is brought into contact with the connecting region and heat is supplied. An interdiffusion layer is formed which fixedly connects the second component and the connecting region to one another and thus joins the first component to the second component.

A wing-box structure for an aircraft is disclosed having an upper cover, a lower cover, longitudinal forward and rearward spars, and a plurality of transverse ribs. One of the transverse ribs is retained by a pair of opposed captive features disposed on an interior side of either the forward and rearward spars or the upper and lower covers. The rib is bonded rib to the forward and rearward spars and/or the upper and lower covers at a location where the rib is retained.

A method is provided for joining thermoplastic components. During this method, a skin is provided that is configured from or otherwise includes a skin fiber-reinforced thermoplastic composite. A support member is provided that is configured from or otherwise includes a support member fiber-reinforced thermoplastic composite. A shim is arranged at an interface between the skin and the support member. The shim is configured from or otherwise includes a shim fiber-reinforced thermoplastic composite. The support member is welded to the skin through the shim at the interface.

A method of joining segments of non-metallic pipe and an apparatus that may be used to form the joint. The pipes may be joined using by melting the ends to form a butt joint, then the joint may be wrapped with one or more sheets of reinforcement material (e.g., pre-impregnated fiberglass, carbon fiber, or aramid fiber). The reinforcement material may be heated using a heating apparatus which allows the material to bond to the pipes to strengthen the joint.

A joint between dissimilar thermoplastic materials comprising a first thermoplastic material layer; a second thermoplastic material layer having a melting point temperature different from a melting point temperature of the first thermoplastic material layer; and an interface layer coupled between the first thermoplastic material layer and the second thermoplastic material layer; wherein the interface layer is configured to join the first thermoplastic material layer and the second thermoplastic material layer together to form the joint, wherein the interface layer comprises a melting point temperature having a value selected from the group consisting of between the melting point temperature of the first thermoplastic material layer and the melting point temperature of the second thermoplastic material layer; or lower than the melting point temperature of the first thermoplastic material layer and the melting point temperature of the second thermoplastic material layer.

A joining method and assembly for an aircraft. To improve the characteristics or permit hitherto impossible connections between thermoplastic and thermoset components, a multi-material joining method is disclosed in which a thermoplastic connecting region is formed on the thermoplastic component. The connecting region is connected to the thermoset component by interdiffusion. For this purpose, the uncured second component is brought into contact with the connecting region and heat is supplied. An interdiffusion layer is formed which fixedly connects the second component and the connecting region to one another and thus joins the first component to the second component.

A method for bonding a composite material includes impregnating a first composite material containing reinforcing fibers and a second composite material containing reinforcing fibers with a resin and bonding them together. A plurality of protruding members each including a plurality of protrusions protruding in mutually different directions are placed on a surface of the first composite material, and the second composite material is placed where the protruding members are placed. The protruding members are introduced into the interior of the first composite material and the interior of the second composite material while causing the first composite material and the second composite material to come into contact with each other. The first and second composite material are bonded in a state where the protruding members are introduced therein, by curing the resin with which the first and second composite material are impregnated.

A system and method for welding thermoplastic components by positioning and moving a heated plate between the components to melt their respective faying surfaces, and as the plate moves, pressing the components together so that the melted faying surfaces bond together as they cool and re-solidify, thereby creating a composite structure. The plate has a heated portion which is positioned between and heated to melt a portion of the first and second faying surfaces. A manipulator mechanism moves the plate along an interface from between the portion to between a series of subsequent portions of the first and second faying surfaces, thereby welding the thermoplastic components along the entire interface to create the composite structure. The heated portion may contact the faying surfaces and melt them through conduction, or may be suspended between them and melt them through radiation and convection.

Various embodiments disclosed relate to an energy converting film. The energy converting film comprises a polymer component. The energy converting film further comprises a susceptor component at least partially distributed in the polymer component.