A method and device for thermal activation of tube-shaped packaging sleeves made of cardboard/plastic composite material, wherein a hot gas is applied to the tube-shaped packaging sleeve by a heating device in order to produce the base or the head of the packaging. To achieve even heating for the activation of the contact surfaces with production using simple construction, wherein the energy required for the activation process is used as completely as possible for the heating of the surfaces to be activated, the heating device is placed into effective contact with the surfaces to be activated by the heating device being moved inside the tube-shaped packaging sleeves for activation. The heating device has at least one nozzle element with an outlet opening, the external shape of which nozzle element corresponds to the internal shape of the end of the tube-shaped packaging sleeve to be activated.

A method for fusing thermoplastic composite structures includes placing a substructure on an inner surface of a skin that is laid up on a shaping surface of a tool configured to maintain the shape of an outer mold line. The method further includes applying at least one insulation layer over a flange of the substructure and over exposed portions of the inner surface of the skin not in contact with the substructure, and applying a vacuum bag to at least partly enclose the skin and the substructure. The method yet still further includes applying heat to the shaping surface to fuse the substructure to the skin such that the skin exceeds its melting point and at least a portion of a raised segment of the substructure does not exceed its melting point.

An automated fiber-placement method comprises delivering a first quantity of pulsed energy to first portions of at least one fiber-reinforced tape strip, and delivering a second quantity of pulsed energy to second portions of at least the one fiber-reinforced tape strip, alternating with the first portions. Each one of the second portions at least partially overlaps two adjacent ones of the first portions such that overlapping regions of the first portions and the second portions have a higher temperature than non-overlapping regions of the first portions and the second portions. The automated fiber-placement method further comprises laying down at least the one fiber-reinforced tape strip against a substrate along a virtual curvilinear path, such that (i) at least the one fiber-reinforced tape strip is centered on the virtual curvilinear path, and (ii) the overlapping regions are transformed into discrete tape-regions, geometrically different from the overlapping regions.

A method for fusing thermoplastic composite structures includes placing a substructure on an inner surface of a skin that is laid up on a shaping surface of a tool configured to maintain the shape of an outer mold line. The method further includes applying at least one insulation layer over a flange of the substructure and over exposed portions of the inner surface of the skin not in contact with the substructure, and applying a vacuum bag to at least partly enclose the skin and the substructure. The method yet still further includes applying heat to the shaping surface to fuse the substructure to the skin such that the skin exceeds its melting point and at least a portion of a raised segment of the substructure does not exceed its melting point.

An article of manufacture comprises a strip that extends along and is centered on a virtual curvilinear path, comprising an arc, having an arc length and a radius. A ratio of the strip-width to the radius is greater than or equal to 0.003. The arc length is equal to or greater than a product of the radius and /64. Within each of discrete strip-regions of the strip, one of the unidirectional reinforcement fibers that is closest to the first longitudinal strip-edge is more buckled than another one of the unidirectional reinforcement fibers that is closest to the second longitudinal strip-edge. Ones of the unidirectional reinforcement fibers that are buckled are parallel to a smallest one of virtual surfaces, joining the first longitudinal strip-edge and the second longitudinal strip-edge.

An automated fiber-placement method comprises delivering a first quantity of pulsed energy to first portions of at least one fiber-reinforced tape strip, and delivering a second quantity of pulsed energy to second portions of at least the one fiber-reinforced tape strip, alternating with the first portions. Each one of the second portions at least partially overlaps two adjacent ones of the first portions such that overlapping regions of the first portions and the second portions have a higher temperature than non-overlapping regions of the first portions and the second portions. The automated fiber-placement method further comprises laying down at least the one fiber-reinforced tape strip against a substrate along a virtual curvilinear path, such that (i) at least the one fiber-reinforced tape strip is centered on the virtual curvilinear path, and (ii) the overlapping regions are transformed into discrete tape-regions, geometrically different from the overlapping regions.

An article of manufacture (200) comprises a strip (202) that extends along and is centered on a virtual curvilinear path (128), comprising an arc (156), having an arc length (154) and a radius (134). A ratio of the strip-width (208) to the radius (134) is greater than or equal to 0.003. The arc length (154) is equal to or greater than a product of the radius (134) and /64. Within each of discrete strip-regions (222) of the strip (202), one of the unidirectional reinforcement fibers (132) that is closest to the first longitudinal strip-edge (204) is more buckled than another one of the unidirectional reinforcement fibers (132) that is closest to the second longitudinal strip-edge (206). Ones of the unidirectional reinforcement fibers (132) that are buckled are parallel to a smallest one of virtual surfaces, joining the first longitudinal strip-edge (204) and the second longitudinal strip-edge (206).

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.

Plastic parts are welded in a laser welding system. An infrared laser source in a laser chamber is controlled by a controller using closed-loop feedback control with a corrected feedback signal that is compensated for background infrared radiation in the laser chamber. Prior to the infrared laser source being turned on, the controller senses with the optical sensor an intensity of background infrared radiation in the laser chamber. Once the laser is on, the controller senses with the optical sensor an intensity of infrared laser radiation in the laser chamber. The controller calculates the corrected feedback signal by subtracting the intensity of the background infrared radiation sensed when the infrared laser source was off from the intensity of the infrared laser radiation sensed when the infrared laser source is on.

Described is a heated gaseous welder system and associated methods of welding plastic with the heated gaseous welder system. The heated gaseous welder system includes a welding tool and a welder control unit. The welder control unit includes a gaseous control system and a heater control system. The gaseous control system is configured to selectively supply a gas to the welding tool and control at least one characteristic of the gas supplied to the welding tool. The heater control system is configured to selectively control power supplied to the welding tool.