A method of bonding a connector to a first object includes providing the connector, the connector being separate from the first object and including a thermoplastic material; arranging the first object and the connector relative to one another so that the connector reaches from a proximal side of the object through a first opening in the object; generating and applying vibrations and mechanical pressure to the connector until a flow portion of the thermoplastic material is liquefied and caused to flow sideways radially into an open space; and removing the source of the vibrations and causing the liquefied thermoplastic material to re-solidify, resulting in the connector with a foot portion, a head portion, and a shaft portion between the foot portion and the head portion. The shaft portion extends along an axis through the first opening, and secures the connector to the first object.

A method of forming a device having a compliant member includes applying heat to a thermoplastic elastomer to maintain the thermoplastic elastomer in a softened state. The thermoplastic elastomer is extruded in the softened state as a film of thermoplastic elastomer. One or more of a bobbin and a housing, each having and end, is positioned such that the end extends at least partially into the film of thermoplastic elastomer. The positioning occurs when the thermoplastic elastomer is in the softened state and/or the bobbin and/or housing is at a temperature that is greater than a temperature of the film of thermoplastic elastomer. The film is cooled so that the bobbin and/or housing are secured to the film and so that the thermoplastic elastomer is in a state that exhibits rubber-like properties.

A method of bonding a connector to a first object includes providing the connector, the connector being separate from the first object and including a thermoplastic material; arranging the first object and the connector relative to one another so that the connector reaches from a proximal side of the object through a first opening in the object; generating and applying vibrations and mechanical pressure to the connector until a flow portion of the thermoplastic material is liquefied and caused to flow sideways radially into an open space; and removing the source of the vibrations and causing the liquefied thermoplastic material to re-solidify, resulting in the connector with a foot portion, a head portion, and a shaft portion between the foot portion and the head portion. The shaft portion extends along an axis through the first opening, and secures the connector to the first object.

A method is provided for connecting a fitting to a reinforced thermoplastic duct including inserting a first end of the fitting having a plurality of barbs into an end of the duct. A clamp is installed around the duct. The duct is heated to a temperature greater than a glass transition temperature of a thermal plastic material used to form the duct. The duct is restructured to include a plurality of protrusions positioned between the plurality of barbs of the fitting.

Process for forming a permanent join between two sections of fibrous material contained in a thermosetting resin matrix, said process comprising overlaying the two sections and subjecting the overlaid sections to ultrasonic welding to form a permanent join between the two sections, wherein there is no significant change in the sub-ambient Tg of the fibrous material contained in the thermosetting resin matrix in the region of the permanent join.

A method for manufacturing a flexible metal-clad laminated plate includes the steps of: (a) obtaining a laminated body by laminating a polyimide resin film including a non-thermoplastic polyimide layer and an adhesive layer containing thermoplastic polyimide, the adhesive layer being provided on at least one side of the non-thermoplastic polyimide layer, and a metal foil; and (b) subjecting the laminated body obtained in the step (a) to heat treatment under an inert gas atmosphere and a pressure of 0.20 to 0.98 MPa at a temperature of a glass transition temperature Tg of the thermoplastic polyimide20 C. to the glass transition temperature Tg+50 C.

Methods and apparatuses for bonding polymeric parts are disclosed. Specifically, in one embodiment, the polymeric parts are bonded by plastically deforming them against each other while they are below the glass transition temperatures.

A multi-material assembly is provided, as well as methods of making a multi-material assembly. The multi-material assembly includes a first coated structural component and a second structural component. The first coated structural component includes a first uncoated portion, and an adhesive is positioned between the second structural component and the first uncoated portion that secures the first coated structural component to the second structural component.

The invention relates to a process for the production of at least two-layer thermoplastic sheets via thermal welding of at least one thinner thermoplastic sheet with density (D1) and of at least one second thinner thermoplastic sheet with density (D2), where the density (D1) of the first thinner thermoplastic sheet is smaller than the density (D2) of the second thinner thermoplastic sheet. The process introduces at least one first heating element and at least one second heating element along mutually offset planes between the two thinner thermoplastic sheets, where the surfaces of the thinner thermoplastic sheets do not touch the surfaces of the heating elements. The first heating element transfers a quantity of energy (E1) to the surface of the first thinner thermoplastic sheet, and the second heating element transfers a quantity of energy (E2) to the surface of the second thinner thermoplastic sheet, where the quantity of energy (E1) is smaller than the quantity of energy (E2).

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.