A method of induction welding a first carbon fiber thermoplastic composite (TPC) to a second carbon fiber thermoplastic composite (TPC) using an induction coil includes aligning the first TPC with the second TPC to form a weld interface area, flexing a heat sink onto a surface of the first TPC between the weld interface area and the induction coil, and inductively heating the weld interface area with the induction coil.

A composite sandwich panel includes a first composite part and a second composite part. A plurality of stiffeners extend between the first and second composite parts. A fiberglass composite perimeter edge closeout is positioned along one or more edges of the first and second composite parts. The fiberglass composite perimeter edge closeout controls a magnetic flux to bond the first and second composite parts to the plurality of stiffeners.

A connecting arrangement includes a first plastic component, a second plastic component, and a closed induction ring that is arranged between the first and second plastic components in a joining gap that is partially filled with molten plastic. The first plastic component has a first joining region that is configured as a stepped receiving opening with a first joining contour. The second plastic component has a second joining region that is configured as a stepped shoulder with a second joining contour. The second joining region is inserted into the first joining region to form the joining gap. The first and second joining contours are adapted to one another so as to center the first joining region, the second joining region, and the induction ring in the joining gap with respect to one another. A method in one embodiment includes welding the first and second plastic components of the connecting arrangement.

A system and method for bonding a first layer of material to a second layer of material includes a first electrically conductive plate, a second electrically conductive plate spaced apart from the first electrically conductive plate. The second electrically conductive plate is electrically grounded. A high frequency generator in electrical communication with the first electrically conductive plate supplies high frequency electrical signals to the first electrically conductive plate. An adhesive applied to one of the first and second layers of material has an electromagnetic susceptor material that when subjected to the electric field heats the adhesive to an adhesive curing temperature to bond the first layer of material to the second layer of material. A clamping mechanism applies pressure to one of the first and second layers of material to maintain contact between the first and second layers until an adhesive cure time has lapsed.

A heat sink for use in induction welding includes a number of tiles, wherein the tiles are electrically non-conductive and have a thermal diffusivity of greater than about 25 mm2/sec. A joint flexibly joins the tiles together.

A system for controlled induction welding of at least one weld seam area (A) of at least two surfaces of at least one workpiece is provided. The system comprises an inductor configured to be arranged in conjunction with the at least one workpiece, a processing means configured to generate an electromagnetic field by applying an alternating voltage to the inductor so as to inductively heat at least one of the surfaces so that the weld seam area (A) is welded together, simultaneously measure at least one parameter (P) of the at least one workpiece at least based on the generated electromagnetic field, detect a change of the at least one parameter (P), and determine a temperature estimation of the at least one workpiece based on said detected change.

A fuselage structure of an aircraft includes a fuselage skin, and a plurality of frame elements spaced apart from one another in a direction parallel to the aircraft longitudinal axis for supporting the fuselage skin. The fuselage skin includes a plurality of interconnected fiber-reinforced composite skin panels that extend between each pair of frame elements and are connected thereto. The composite skin panels further comprise a stiffener integrally formed in each composite skin panel. A method for manufacturing the fuselage skin. The composite skin panels may be interconnected and/or connected to a frame element through an induction welded connection.

A heat sink for use in induction welding includes a number of tiles, wherein the tiles are electrically non-conductive and have a thermal diffusivity of greater than about 25 mm2/sec. A joint flexibly joins the tiles together.

A heatsink, a method of manufacturing the heatsink, and an induction welding apparatus including the heatsink. The heatsink includes a carrier sheet and a plurality of tiles. The carrier sheet comprises an electrically non-conductive material and has a contoured profile. The plurality of tiles comprises a thermally conductive and electrically non-conductive material. Each tile of the plurality of tiles has a bonding surface bonded to the carrier sheet and a contact surface opposite the bonding surface. The contact surface is configured to contact a structure to be induction welded.

A method for manufacturing a current collector head for a current collector consisting of an electrically conductive contact shoe and an electrically insulating contact shoe holder includes the following steps: inserting a section of the contact shoe into an outwardly open cavity in the contact shoe holder dimensioned to match this section; clamping the contact shoe in the cavity of the contact shoe holder by acting on the contact shoe holder with at least an external force directed onto the inserted section of the contact shoe; heating the contact shoe to a temperature sufficient to form a bonded connection with the contact shoe holder; and cooling the current collector head formed from the contact shoe and the contact shoe holder.