An expansion-molded article that can be firmly heat-fused with another member is provided. The expansion-molded article is one that may be heat-fused with another member, where the expansion-molded article includes at least one protrusion which is formed on at least one surface of the expansion-molded article including at least one surface is to be heat-fused with the another member. The at least one protrusion comprises at least two surfaces as viewed from above, and a boundary line between the at least two surfaces, where the at least one boundary line intersects a direction from an outside of the at least one protrusion toward a center of an apex of the at least one protrusion.

A method for joining two objects by anchoring an insert portion provided on a first object in an opening provided on a second object. The anchorage is achieved by liquefaction of a thermoplastic material and interpenetration of the liquefied material and a penetrable material, the two materials being arranged on opposite surfaces of the insert portion and the wall of the opening. During the step of inserting the insert portion in the opening and/or during anchorage a clamping force is applied to opposing surfaces of the second object to prevent the second object from cracking or bulging.

Methods of bonding a first object to a second object, including the steps of: providing the second object having a protrusion; providing the first object having a thermoplastic material; positioning the first object relative to the second object such that an assembly of the first and the second object is formed; applying a relative force between the second and first objects and applying mechanical vibration to the assembly of the first and the second object until at least a flow portion of the thermoplastic material becomes flowable and flows around the protrusion; and causing the thermoplastic material to re-solidify. The first object may be a connecting element including a feedthrough, wherein the second object has a corresponding opening. The protrusion may be deformed such that the protrusion has an undercut relative to an axis along which the first and second objects are pressed against each other.

Methods for ultrasonic welding of thermoplastic polymer workpieces and assemblies made therefrom are provided. The method may comprise disposing a first region of a first thermoplastic polymer workpiece and a second region of a second thermoplastic polymer workpiece between an ultrasonic horn and an anvil of an ultrasonic welding device. The first workpiece has a preformed deformation and at least one of the first and/or second workpieces has an adhesive precursor applied thereto. The ultrasonic horn or anvil seats within the preformed deformation. Ultrasonic energy is applied from the ultrasonic horn to create a weld nugget between the first and second workpieces. The assembly thus formed has a green strength sufficient to be further processed immediately. The methods provide a robust weld joint with controlled adhesive bondline thickness.

A method for joining two objects by anchoring an insert portion provided on a first object in an opening provided on a second object. The anchorage is achieved by liquefaction of a thermoplastic material and interpenetration of the liquefied material and a penetrable material, the two materials being arranged on opposite surfaces of the insert portion and the wall of the opening. During the step of inserting the insert portion in the opening and/or during anchorage a clamping force is applied to opposing surfaces of the second object to prevent the second object from cracking or bulging.

A first aspect of the invention provides a method of joining a part to a composite component, the composite component comprising fibres impregnated with a matrix material, and the part comprising a plurality of projections, the method comprising: inserting the projections into the composite component; and pre-heating the projections before they are inserted into the composite component, so that the projections are at a higher temperature than the composite component as they are inserted into the composite component. The projections locally heat the matrix material of the composite component as they are pushed into the composite component. Increased temperature during insertion is advantageous as the reduced matrix viscosity, due to the increased temperature of the matrix, results in better consolidation of the fibres around the projections and minimises the distortion of the fibres. The composite component is only heated locally where heating is required, which removes the need to heat the entire composite component.

A method of mechanically securing a first object including a thermoplastic material in a solid state to a second object with a generally flat sheet portion, with a perforation of the sheet portion, and with the sheet portion having an edge along the perforation is provided, wherein the first object is positioned relative to the second object so that the edge is in contact with the thermoplastic material and wherein mechanical vibration energy is coupled into the assembly including the first and second objects until a flow portion of the thermoplastic material due to friction heat generated between the edge and the thermoplastic material becomes flowable and flows around the edge to at least partially embed the edge in the thermoplastic material. After the mechanical vibration stops, the thermoplastic material is caused to re-solidify, whereby the re-solidified thermoplastic material at least partially embedding the edge anchors the first object in the second object.

A wing leading edge assembly is disclosed including a leading edge panel and a cover panel located over the structural component. The cover panel has a thermoplastic layer with an inner surface. A thermoplastic fastening member extends through the structural component and is welded to the inner surface so that the structural component is fastened between the inner surface and the fastening member.

A method of mechanically securing a first object including a thermoplastic material in a solid state to a second object with a generally flat sheet portion, with a perforation of the sheet portion, and with the sheet portion having an edge along the perforation is provided, wherein the first object is positioned relative to the second object so that the edge is in contact with the thermoplastic material and wherein mechanical vibration energy is coupled into the assembly including the first and second objects until a flow portion of the thermoplastic material due to friction heat generated between the edge and the thermoplastic material becomes flowable and flows around the edge to at least partially embed the edge in the thermoplastic material. After the mechanical vibration stops, the thermoplastic material is caused to re-solidify, whereby the re-solidified thermoplastic material at least partially embedding the edge anchors the first object in the second object.

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.