Methods for manufacturing elongated structural elements are provided. Such methods provide composite material having optimal properties such as weight and strength which can be produced at much lower costs compared to conventional methods. Composite materials including such elements are also provided. In addition, commercial products incorporating such structural elements are provided.

A rotary wing aircraft that comprises a structural arrangement with at least one first fiber reinforced polymer component and at least one second fiber reinforced polymer component that are spaced apart from each other by an interspace and that are rigidly attached to an associated structural component, wherein the at least one first fiber reinforced polymer component and the at least one second fiber reinforced polymer component are at least partly interconnected by means of an electrically conductive connection, and wherein the electrically conductive connection comprises at least one sprayed layer of electrically conductive particles, the at least one sprayed layer of electrically conductive particles being provided in the interspace.

Methods for manufacturing elongated structural elements are provided. Such methods provide composite material having optimal properties such as weight and strength which can be produced at much lower costs compared to conventional methods. Composite materials including such elements are also provided. In addition, commercial products incorporating such structural elements are provided.

A method for joining a metal material element to a plastic material element, in particular a composite material including a plastic matrix reinforced with fibers for use in the construction of motor-vehicle components. The method involves providing one or more slots in a portion of the plastic material element. For each slot, a corresponding tab is provided in the metal material element, having a shorter width and length than a width and length of the slot. The metal material and plastic material elements are arranged in a position of mutual coupling where each tab is inserted through the corresponding slot and has an end portion protruding beyond said portion of the plastic material element. A laser beam is directed above the protruding end portion, so as to locally melt the metal material of each tab and create an enlarged head on each tab that is welded above the plastic material element.

A composite molded article contains a metal molded article and a resin molded article, which are bonded to each other, in which the metal molded article has a roughened bonding surface, a surface layer portion of the metal molded article including the roughened bonding surface has: open holes containing: a stem hole that is formed in a thickness direction and has an opening on the side of the bonding surface, and a branch hole that is formed from an inner wall of the stem hole in a different direction from the stem hole, and the composite molded article is bonded in such a state that the resin permeates into the open holes formed on the bonding surface of the metal molded article.

A method for assembling a shear web assembly of a wind turbine includes providing at least one spar cap. The method also includes forming a spar connecting member of a thermoplastic material via additive manufacturing. Further, the method includes securing the spar connecting member to the spar cap. Moreover, the method includes providing a shear web, forming a web connecting member of a thermoplastic material via additive manufacturing, and securing the web connecting member at a first end of the shear web. In addition, the method includes interconnecting the web connecting member and the spar connecting member at a joint. Thus, the method further includes heating the joint to secure the web connecting member and the spar connecting member together.

A method of forming a composite preform containing multiple laminates is disclosed. The method may include providing a first sublaminate comprising stacked fibers woven into a fabric; providing a second sublaminate comprising stacked fibers woven into a fabric; joining the first sublaminate and the second sublaminate forming a component comprising a region of discontinuity sandwiched between the first sublaminate and the second sublaminate; rigidizing the component; and softening the region between the first sublaminate and the second sublaminate. In illustrative embodiments, the method may include manipulating the region of discontinuity between the first sublaminate and the second sublaminate to reduce the incoherence between the sublaminates by moving fibers from the sublaminates through at least part of the region between the first sublaminate and the second sublaminate.

A rotor blade for a wind turbine may generally include a first blade component formed from a first fiber-reinforced composite including a first thermoplastic resin material and a second blade component configured to be coupled to the first blade component at a joint interface. The second blade component may be formed from a second fiber-reinforced composite including a second thermoplastic resin material. The second fiber-reinforced composite may include a low fiber region and a high fiber region, with the low fiber region having a fiber-weight fraction that is less than a fiber-weight fraction of the high fiber region. In addition, the first thermoplastic resin material of the first fiber-reinforced composite may be welded to the second thermoplastic resin material contained within the low fiber region of the second thermoplastic composite to form a welded joint at the joint interface between the first blade component and the second blade component.

Exemplary embodiments are disclosed of liners, linings, and liquid containment vessels including the same. Also disclosed are exemplary method of providing liners and linings for liquid containment vessels, such as process tanks, immersion tanks, containment pits, gravity feed conduits for transferring or conveying liquid, etc. In an exemplary embodiment, a liner or lining is anchored to at least one structural component by at least one extrusion weld and at least one mechanical fastener. The mechanical fastener is coupled to the structural component. The extrusion weld is coupled to the mechanical fastener. The liner or lining may be anchored to a wide range of structural components, such as a frame, a framework, a frame member, a tank, a wall, a support member, a reinforcing member, an outer shell, a substrate (e.g., concrete, etc.) or sidewalls defining a pit or a gravity feed conduit, combinations thereof, other structures or components, etc.

A respiratory apparatus may employ ultrasonic welds. The ultrasonic welding may be used to join a variety of headgear, mask and accessory components. This process may enhance comfort, fit and/or performance of the joined components and/or overall mask assembly. A component may be a single layer component such as a textile or fabric, or a composite or multiple layer component such as fabric and foam composites, or outer fabric layers and inner spacer fabrics. Further, a component may be a strap, some other headgear component, a mask component, an accessory component or the like.