A fiber-reinforced thermoplastic resin member welding method includes: heating, by a heating unit, a welding target portion in which plural fiber-reinforced thermoplastic resin members layered on top of each other, each of the plural fiber-reinforced thermoplastic resin members including thermoplastic resin as a main composition, and the thermoplastic resin including reinforcing fibers; applying pressure, by a pressure applying unit, to the welding target portion; and cooling, by a cooling unit, at least a surface of the welding target portion at the same time as when the welding target portion is being heated by the heating unit or after the welding target portion has been heated by the heating unit.

A method of repairing a polymeric composite workpiece. The method comprises identifying a localized area of the polymeric composite workpiece having a defect. A plurality of three dimensional interface structures are aligned adjacent at least a portion of the localized area. The method includes applying a polymeric composite patch to the localized area such that the interface structures are disposed between the polymeric composite workpiece and the polymeric composite patch. An alternating electromagnetic field may be introduced to selectively induce localized heating of the interface structures. The localized heating softens regions of the polymeric composite workpiece and the polymeric composite patch adjacent the interface structures, causing the interface structures to penetrate a distance into the respective polymeric composite workpiece and the polymeric composite patch.

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 method for producing, by welding, a joint between a thermoplastic matrix composite material and an elastomeric material. The elastomeric material is functionalized by incorporating, onto the surface of the elastomer, a nonwoven fabric consisting of fibers of thermoplastic material. The functionalized surface of the elastomeric material is welded to the thermoplastic material of the composite. The functionalization of the elastomeric material is performed during the vulcanization of the raw elastomer. The vulcanization is performed under a sufficient pressure for the nonwoven fabric placed on the surface of the raw elastomer to become incorporated with same, at least at the surface, during the vulcanization process. The welding operation includes interposing a metal fabric coated with thermoplastic material between the surfaces of the elastomer and the composite that are welded to each other, and passing an electric current through same, resulting in the surface melting of the two materials.

A method for producing, by welding, a joint between a thermoplastic matrix composite material and an elastomeric material. The elastomeric material is functionalized by forming a thin layer of elastomeric material incorporating particles of thermoplastic material and melting the thin layer onto the surface of the elastomeric material during the pressure-vulcanization of the elastomer. The functionalized surface of the elastomeric material is welded to the thermoplastic material of the composite. The welding operation includes interposing a metal fabric coated with thermoplastic material between the surfaces of the elastomer and the composite that are welded to each other, and passing an electric current through same, resulting in the surface melting of the two materials.

Composite joints and methods of forming composite joints are presented. A composite joint comprising: a first composite component formed of one of a thermoset material or a first thermoplastic material; a second composite component formed of a thermoset material or a third thermoplastic material; a thermoplastic joining film formed of a second thermoplastic material between the first composite component and the second composite component, the second thermoplastic material different from the thermoset material, first thermoplastic material, and third thermoplastic material; and a carbon conductive layer in the thermoplastic joining film.

A method and apparatus for welding a thermoplastic structure. The apparatus comprises a base, a cover, and a channel. The base is formed of a material that is magnetically opaque to a frequency in a range of 30 KHz to 350 KHz. The cover is formed of the material. The channel extends between the base and the cover.

A component includes at least first and second plastics component parts which are interconnected in a connection zone. A reinforcing element includes at least one wire which bridges the connection zone. The first and second plastics component parts are welded together and/or are fused together in the connection zone. The plastics component parts may be bonded to one another.

A kit for fusing piping includes a plurality of couplings, each coupling having a susceptor layer concentric with a weld zone. A control unit provides a current to a wand with a handle for gripping by a user. The handle has opposing jaws mounted on the distal end, each jaw including an arcuate conductor such that the arcuate conductors form a circular inner diameter when the jaws make contact. A lever system couples to the distal end for opening and closing the jaws. The lever system includes a spring for selectively biasing the lever system in a latched position with jaws closed and an open position with the jaws open. Each coupling is sized such that the jaws will only close about the weld zone. The arcuate conductors create a fuse zone about the susceptor layer and the spring is outside the fuse zone.

A reel includes a core, a first flange affixed to a first end of the core, a second flange affixed to a second opposite end of the core, and a first bonded joint connecting the first flange to the core. The first bonded joint includes a first susceptor material arranged between the first flange and the first end of the core, and the first flange and the first end of the core are bonded around the first susceptor material.