Composite laminate structures are produced using partially cured parts. Partial curing of the parts is achieved by applying a catalyst to regions of the parts that are to be fully cured. These regions cure at a lower-than-normal temperature while remaining regions of the part remain uncured, allowing them to be co-bonded or co-cured to other structures.

A joining method is provided during which a first thermoplastic component joint section and a second thermoplastic component joint section are arranged between first tooling and second tooling. The second thermoplastic component joint section is abutted against the first thermoplastic component joint section at a joint area. The first thermoplastic component joint section is joined to the second thermoplastic component joint section to provide a unitized thermoplastic structure. The joining includes: pressing the first thermoplastic component joint section against the second thermoplastic component joint section at the joint area between the first tooling and the second tooling using a pressure device; and heating the first thermoplastic component joint section and the second thermoplastic component joint section at the joint area using a first heater configured with the first tooling. The unitized thermoplastic structure is cooled at the joint area using a first cooler configured with the first tooling.

A method for manufacturing a thermoplastic composite product includes: providing a first and second thermoplastic composite component made from a consolidated stack of thermoplastic composite plies, said first and second component having a first and second ply drop off, respectively. The first and second components are positioned such that the first ply drop off and the second ply drop off are aligned, and the first and second components are fixedly connected by means of heating. The stacks of plies for the first and second components are constructed by stacking the plies in a stacking direction wherein the plies are arranged such that plies at a different position along the stacking direction are laterally offset relative to each other for the purpose of forming the first ply drop off and the second ply drop off, respectively, before consolidating.

A first thermoplastic component and a second thermoplastic component including a first joint portion and a second joint portion, respectively, are provided. A least a portion of a surface area of each of the first and second joint portions include a respective first and second mating surface. The first and second mating surfaces of the respective first and second joint portions are positioned in contact with one another. The first and second joint portions are fusion joined. Fusion joining the first and second joint portions forms a fused unitary portion of the first and second thermoplastic components.

Systems and methods are provided for utilizing stringer end caps. One embodiment is a method of forming a stringer. The method includes laying up a stringer preform comprising fiber-reinforced material, placing the stringer preform onto a skin panel preform, bonding an end cap to the stringer preform and the skin panel preform, and co-curing the stringer preform and the skin panel preform while the end cap is bonded to the stringer preform and the skin panel preform, resulting in a composite part that includes the end cap.

A method for joining two substantially planar fiber-composite structural components, includes stacking the two components on a support jig to overlap along a joining region. A lower component end section within the joining region borders a gap between the upper component and the jig, where the upper component is unsupported by the jig. The gap is bordered on an opposite side of the lower component end section by a filling portion of the upper component or a planar filler element supported by the jig. The lower component is joined to the upper component within the joining region by applying temperature and pressure to the components. A width of the gap allows the upper component to elastically deform along the gap under the pressure and bend down into the gap to abut the jig along the gap and thereby compensate thickness tolerances between the components during the pressure application.

Construction of a sealed connection between an elastomeric or synthetic polymer flexible pipe or hose and a metallic coupling member. The coupling member surrounds an armor layer at a free end of the flexible pipe or hose. A sealing area is defined by a recessed portion of the pipe coupling into which a sealing material is introduced. An inner liner layer of the flexible pipe or hose may extend into the sealing area where it is bonded to the sealing material. The sealing material and the inner liner layer may each be comprised of a semi-crystalline thermoplastic material. Furthermore, a reinforcement material may be provided in the inner liner layer.

A first thermoplastic component and a second thermoplastic component including a first joint portion and a second joint portion, respectively, are provided. A least a portion of a surface area of each of the first and second joint portions include a respective first and second mating surface. The first and second mating surfaces of the respective first and second joint portions are positioned in contact with one another. The first and second joint portions are fusion joined. Fusion joining the first and second joint portions forms a fused unitary portion of the first and second thermoplastic components.

Systems and methods are provided for utilizing stringer end caps. One embodiment is a method of forming a stringer. The method includes laying up a stringer preform comprising fiber-reinforced material, placing the stringer preform onto a skin panel preform, bonding an end cap to the stringer preform and the skin panel preform, and co-curing the stringer preform and the skin panel preform while the end cap is bonded to the stringer preform and the skin panel preform, resulting in a composite part that includes the end cap.

Systems and methods are provided for fabricating composite parts. One embodiment is a method for fabricating a composite part. The method includes forming a skin panel preform comprising fiber reinforced material, disposing rigid end caps at the skin panel preform at end locations of stringer preforms that will be placed at the skin panel, locating the stringer preforms at the skin panel preform via the rigid end caps, and anchoring the stringer preforms to the skin panel preform.