A joining method for connecting at least two thermoplastic workpieces is provided to permit the joining even of non-transparent carbon fiber reinforced plastics parts by means of laser welding, in which a splice is produced at the edge regions of the workpieces and the workpieces are subsequently positioned relative to one another in such a manner that the opposite splice regions bound a seam region. Connecting bodies are then inserted into the seam region and heated by means of local heat input by laser beam such that a fixed integrally bonded connection forms between the workpieces and the connecting bodies.

A housing, in particular a battery housing, includes a wall, wherein the wall is formed, at least is some areas, from a multi-layered material. The wall encompasses an arrangement area which is formed by bending the material.

Methods include providing a plurality fabric material layers, applying a plastisol layer between each fabric material layer forming plurality fabric material layers thereby creating a belt carcass, pressing the fabric material layers together with the plastisol layer(s) at a pressure of at least 5 psi to produce a preformed fabric carcass while heating the preformed fabric carcass while heating the preformed fabric carcass to a temperature which is within the range of about 360° F. to about 450° F. for a period of at least 6 minutes, disposing a thermoplastic elastomer polyvinyl chloride alloy composition onto the upper and lower surfaces of the fabric carcass, pressing the thermoplastic elastomer polyvinyl chloride alloy composition onto the upper and lower surfaces of the fabric carcass, and splicing opposing distal ends of the belt in a stepped splice configuration. The layers may be devoid of covering strips of lattice fabric disposed adjacent an abutment of any proximally positioned fabric layer.

A method for repairing rivet tape includes steps of cutting portions of the rivet tape on each side of a break to define at least three aligned coplanar rivet tape edges, abutting the at least three aligned coplanar rivet tape edges to define a seam, and joining the at least three aligned coplanar rivet tape edges to one another. The seam may define a Z shape. One or more rivets may be removed to expose rivet apertures on each side of the break before the steps of cutting, abutting, and joining. The step of joining is accomplished by at least one adhesive strip disposed on a surface of the rivet tape and dimensioned to overlie the at least one or more exposed rivet apertures. Adhesive strips may be disposed on each opposed surface of the rivet tape length. In other aspects, workstations comprise devices for practicing the described methods.

A system using a pressure differential to clamp welding heads on opposite sides of a joint of a thermoplastic composite structure to be welded. The heads are positioned over the joint opposite each other. Each head includes a housing defining a chamber having a lower pressure such that the pressure differential forces the head against the side. Each head includes a contour plate located in the space and against the joint, and at least one of the heads includes a heater located in the space and heating the contour plate to a welding temperature. The system may also include a first arm coupled with one of the heads and moving it along the joint so as to remain aligned with the other head, and a second arm coupled with the other head and moving it along the joint while the system welds the joint in successive overlapping sections.

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.

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.

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.

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.