An insert for load application and/or anchorage of various components into/onto a composite sandwich panel. The insert includes a rotationally symmetric inner insert ring, an outer insert ring, an insert connecting portion connecting the inner insert ring with the outer insert ring, and an insert trench provided between the outer insert ring and the inner insert ring.

A method of forming a thermoplastic cellular structure includes positioning a lower surface of a trough of a first corrugated thermoplastic sheet against an upper surface of a crest of a second corrugated thermoplastic sheet; positioning a support against a lower surface of the crest of the second corrugated thermoplastic sheet; and pressing a thermoplastic welding element against an upper surface of the trough of the first corrugated thermoplastic sheet so that at least a portion of the lower surface of the trough of the first corrugated thermoplastic sheet melts and bonds to at least a portion of the upper surface of the crest of the second corrugated thermoplastic sheet.

A motor vehicle roof shell having a rigid composite component having an inner side facing a vehicle interior, and an acoustic insulation layer disposed on the inner side of the composite component. The panel-type rigid composite component has at least one tray-like recess on its inner side, said recess being filled with an open-pored foam material which forms the acoustic insulation layer and whose surface is flush with a surface of the composite component surrounding the recess. A motor vehicle roof shell motor vehicle having a panel-type rigid composite component having an inner side, which faces the vehicle interior, and an acoustic insulation layer disposed on the inner side of the composite component, wherein the acoustic insulation layer is formed by at least one rigid-foam or semi-rigid-foam plate which is bonded to the inner side of the composite component and compressed that its volume is reduced compared to preassembly state.

A method of fastening an edge structure to a construction element includes providing the construction element, being a planar structure with with two cover regions and a middle region between the cover regions; providing the edge structure being continuously extended, the edge structure having contact surfaces with a thermoplastic material shaped to lie against the cover regions in an outer surface of the construction element, and, opposite the contact surfaces, a coupling-in surface for coupling energy into the edge structure; coupling energy into the edge structure and pressing the contact surfaces against the cover regions until at least a portion of the thermoplastic material is liquefied and pressed into the cover regions; and repeating or continuing the steps of coupling and pressing until the edge structure is attached to the building element at a plurality of discrete locations or over an extended region along an edge of the construction element.

A method of bonding a second object to a first object includes: providing the first object, which includes a thermoplastic liquefiable material in a solid state; providing the second object, which includes a surface portion that has a coupling structure with an undercut such that the second object can make a positive-fit connection with the first object; and pressing the second object against the first object with a tool that is in physical contact with a coupling-in structure of the second object while mechanical vibrations are coupled into the tool. The step of pressing and coupling vibrations into the tool continues until a flow portion of the thermoplastic material of the first object is liquefied and flows into the coupling structures of the second object. Thereafter, the thermoplastic material of the first object is permitted to re-solidify to yield a positive-fit connection between the first and second objects.

The present disclosure relates to a method of repairing a damaged portion of a perforated skin of a panel using a doubler made of composite material which is designed to be applied to the damaged portion of the perforated skin. The method includes at least one step in which a sealing film is applied to the damaged portion of the perforated skin in order to temporarily seal the perforations in the skin, and a step in which the doubler is produced over the previously deposited sealing film.

A method of forming a structural tube may include urging a substantially flat thermoplastic sandwich sheet against a mandrel and heating the thermoplastic sandwich sheet to a temperature below a glass transition temperature. The method may further include allowing the thermoplastic sandwich sheet to cool and removing the mandrel, thereby forming a tube portion.

A method of anchoring a connector in a first object is provided, the connector having a thermoplastic material in a solid state. The method includes providing the first object and the connector, bringing the connector into contact with the first object from a distal side thereof, causing mechanical vibration energy to impinge on the first object from a proximal end face thereof, the proximal end face being opposite the distal side, while the object and the connector are pressed against each other, until a proximally facing end of connector is at least partially flowable forming a flow portion of the thermoplastic material, and causing the flow portion to flow into structures of the first object, and letting the flow portion re-solidify to cause a positive-fit connection between the first object and the connector.

A method for the manufacture of reinforced core composites, comprises: inserting of a pin into a foamed core material or a filled honeycomb-shaped core material, wherein the pin and the core material contain a thermoplastic polymer, or a mixture of thermoplastic polymers; the pin is heated such that as the pin is inserted the core material softens or melts at the point of insertion; and/or the core material is heated at the point of insertion such that the core material softens or melts.

A process for manufacturing an acoustic panel including at least one acoustically resistive layer, at least one cellular structure and a reflective wall. The process includes steps of depositing the parts of the acoustic panel made of thermosetting composite, depositing a film made of thermoplastic resin that is miscible with the thermosetting composite at the polymerization temperature of the thermosetting composite, polymerizing the parts of the acoustic panel made of thermosetting composite, and depositing and consolidating at least one layer made of thermoplastic composite against the film made of thermoplastic resin in order to form the reflective wall.