A thrust reverser blocker door includes a body portion and a mounting structure coupled to the body portion. The body portion includes a facesheet, a backsheet, and a honeycomb core. The facesheet and/or the backsheet comprises a first thermoplastic material and the mounting structure comprises a second thermoplastic material. A method for manufacturing a thrust reverser blocker door may comprise thermoforming a sandwich panel comprising a facesheet, a backsheet, and a honeycomb core. The method may further comprising overmolding a mounting structure onto the backsheet. The first thermoplastic material may comprise a continuous fiber reinforced thermoplastic composite material. The second thermoplastic material may comprise a discontinuous fiber reinforced thermoplastic composite material.

A method of anchoring a first object in a second object is described. The first object extends along an axis between a proximal end and a distal end and has a circumferential surface. The circumferential surface comprises at least one helical protrusion of a thermoplastic material. For anchoring, the first object is brought in contact with the second object, and mechanical vibration is coupled into the first object from a proximally facing coupling-in face thereof so as to drive the first object into the second object in a manner that the vibration and pressing cause the first object to be subject to a helical movement relative to the second object and cause thermoplastic material of the first object to become flowable and to penetrate into structures of the second object to yield, after resolidification, a positive fit connection with the second object.

A system and method for welding two thermoplastic workpieces. The system has an ultrasonic tool, a support and a cooling unit. The ultrasonic tool is configured to generate mechanical vibrations. The system is configured to clamp together workpieces in the receiving region by the ultrasonic tool and the support if at least one fastening portion of the workpieces opposite one another is arranged in the receiving region. The ultrasonic tool is configured to introduce the mechanical vibrations into the fastening portion of the workpieces to weld the workpieces in a joining zone. The cooling unit is configured to cool, with cooling fluid, at least a part of the fastening portion of the workpieces and/or a cooling portion of the workpieces directly adjacent to the fastening portion.

A tool presses a joining element against a first object into a first opening of the first object while mechanical vibration energy is coupled into the first object and the joining element. Vibration energy and pressing force make the thermoplastic material of the distal portion of the joining element flowable and interpenetrates structures of the first object to yield, after re-solidification, an anchoring of the distal portion of the joining element in the first object. The second object is placed so that a proximal portion of the joining element is inserted into a second opening, and the first and second objects are pressed against each other while mechanical vibration energy is coupled into one of the first and second objects, until thermoplastic material of the joining element proximal portion is made flowable and interpenetrates structures of the second object to yield, after re-solidification, an anchoring in the second object.

Embodiments herein include a system for joining components. The system can include a rotating base platform, a plurality of receptacles mounted to the base platform, and a rotating sonotrode platform. A plurality of sonotrodes are mounted to the sonotrode platform. Each sonotrode can correspond to a receptacle. Each sonotrode can move in a reciprocating motion between a release position distant from a corresponding receptacle and a compressing position proximal to the corresponding receptacle. The compressing position occurs at a first angular position of the sonotrode platform. Each sonotrode is energized at the compressing position.

A method of bonding a first object to a second object includes the steps of: providing the first object including thermoplastic material in a solid state, providing the second object including a proximal surface, applying a mechanical pressing force and a mechanical excitation capable to liquefy the thermoplastic material until a flow portion of the thermoplastic material is flowable and penetrates into structures of the second object, and stopping the mechanical excitation and letting the thermoplastic material resolidify to yield a positive-fit connection between the first and the second object. The second object has a region of low density, wherein the protrusion penetrates the region of low density at least partly before the thermoplastic material is made flowable, and wherein the first object includes a protruding portion after the step of letting the thermoplastic material resolidify, the protruding portion at least partly penetrates the region of low density.

A method for transversally sealing a packaging material tube, comprises placing a transversal sealing section of the tube between a sonotrode and an anvil. The transversal sealing section comprises a first two-layer sub-section, a three-layer sub-section and a second two-layer sub-section, transmitting ultrasonic acoustic vibrations, having a frequency and an amplitude, from the sonotrode into the transversal sealing section, thereby melting the plastic foil in the transversal sealing section, and pressing the tube together between the sonotrode and the anvil to bond the plastic foil such that transversal sealing is formed. The anvil has a ridge comprising various sub-sections for receiving various ones of the sub-sections of the tube, wherein the ridge has equal height in at least some of the sub-sections. The frequency, amplitude, pressure and paperboard properties are chosen to achieve equal temperature in the first two-layer sub-section, the three-layer sub-section and the second two-layer sub-section.

A method for manufacturing a welded molding made of liquid crystal polyester as a formation material is provided, the method including: a step of heating each of a first ridge portion of a first member made of the liquid crystal polyester as a formation material and a second ridge portion of a second member made of the liquid crystal polyester as a formation material to a temperature equal to or higher than a flow start temperature of the liquid crystal polyester; and a step of abutting the first ridge portion and the second ridge portion to each other to perform vibration welding while pressing the first ridge portion and the second ridge portion in a direction in which the first ridge portion and the second ridge portion are brought relatively close to each other.

An ultrasonic welding method for joining a first thermoplastic part and a second thermoplastic part without causing visible read-through on an exposed surface of the second part. The method includes arranging the first part on an inner surface of the second part. The inner surface is opposite the exposed surface. The first part has an interface portion contacting the inner surface. The method includes causing a horn of an ultrasonic welding stack to be pressed against the first part by applying ultrasonic energy oscillating at a frequency in a range of 45-70 kHz through the horn, to thereby join the first part and the second part together. The horn has at least one protruding distal portion configured to penetrate through the first part as the ultrasonic energy is imparted through the horn. The distal portion has a length longer than a thickness of the first part. A collapse distance of a weld formed at the interface portion is less than the thickness of the first part, to avoid read-through effects on the exposed surface of the second part.

Embodiments herein include a system for joining components. The system can include a rotating base platform, a plurality of receptacles mounted to the base platform, and a rotating sonotrode platform. A plurality of sonotrodes are mounted to the sonotrode platform. Each sonotrode can correspond to a receptacle. Each sonotrode can move in a reciprocating motion between a release position distant from a corresponding receptacle and a compressing position proximal to the corresponding receptacle. The compressing position occurs at a first angular position of the sonotrode platform. Each sonotrode is energized at the compressing position.