A method for bonding thermoplastic fiber-composite parts comprises providing surface texture on one or both parts being bonded, and/or providing both parts with engagement features. Such surface textures and engagement features have a specific geometry and fiber alignment that facilitate fibrous interlock between the two parts at a bonding interface via in-situ consolidation.

The machine comprises a heating station (20) with hot air supply nozzles (22) facing one another and spaced apart; a unitary dispenser device (30) for dispensing plastic spouts into said heating station by a delivery element; a welding station (40); a gripping device (50) for gripping the plastic spout (5) at said heating station (20) and transferring it to the welding station (40) by turning said plastic spout (5) and placing a portion thereof, once heated, inside the open mouth (M) of a plastic package (2)); and a control unit (60) which manages in a coordinating manner the operation of the heating station (20), the dispenser device (30), the plastic spout delivery element, the gripping device (50) and the welding station (40).

A joining method for joining a resin member and a metal member by heating is provided. Joining of the resin member and metal member is performed by heating a joining interface of the resin member and metal member to a temperature in a range of equal to or higher than a decomposition temperature of the resin member and lower than a temperature at which gas bubbles are generated in the resin member and by cooling a surface of the resin member on the opposite side from a joining surface thereof with the metal member to a temperature that is lower than the melting point of the resin member.

A liftgate assembly having finished show surfaces, and process of manufacturing same. The liftgate assembly includes local reinforcements that are overmolded to first reinforcements, and the first reinforcements are infrared welding to a first panel. Second and third reinforcements are also infrared welded to the first panel. To infrared weld the respective reinforcements to the first panel in predetermined locations with respect to the first panel, nesting structures are provided to hold the respective reinforcements and first panel. At least one infrared heating fixture heats various predetermined surfaces on the reinforcements and first panel, and the parts are then pressed together for joining the predetermined surfaces of the respective parts together. The process is repeated, if needed, until all of the reinforcements are infrared welded to the first panel. Outer panels are bonded to the second and third reinforcements.

The machine comprises a heating station (20) with hot air supply nozzles (22) facing one another and spaced apart; a unitary dispenser device (30) for dispensing plastic spouts into said heating station by a delivery element; a welding station (40); a gripping device (50) for gripping the plastic spout (5) at said heating station (20) and transferring it to the welding station (40) by turning said plastic spout (5) and placing a portion thereof, once heated, inside the open mouth (M) of a plastic package (2)); and a control unit (60) which manages in a coordinating manner the operation of the heating station (20), the dispenser device (30), the plastic spout delivery element , the gripping device (50) and the welding station (40).

A process for welding a first molding to a second molding. The process uses an implement including first and second external surfaces. Each external surface further includes a duct. An end of the first molding is heated by a hot gas while the end is at a distance from the duct-entry plane in the range from 3 mm outside the duct to 10 mm inside the duct. A junction area of the second molding is heated by a hot gas while the junction area is at a distance from the duct-entry plane in a range from 3 mm outside the duct to 10 mm inside the duct. The heated end and the heated junction area are then brought into contact with one another and cooled, forming a weld between the first molding and the second molding. Also disclosed is a welded molding obtainable by the process of the invention.

An article of manufacture that has at least three layers of sealable material. There is at least one first seal between at least two of the layers in a first area having a first sealing affinity effected at a first sealing parameter. There is also at least one second seal between at least two more layers, where at least one of these two layers is distinct from the at least two layers joined by the first seal, in a second area having a second sealing affinity effected at a second sealing parameter, where the second sealing parameter is different than the first sealing parameter, thereby allowing for sealing of discrete areas of the article in discrete steps.

A method for inserting an insert into a hole in a composite material made from a plurality of carbon fiber layers suspended in a resin material includes lowering a temperature of the insert to a reduced temperature at which a coefficient of thermal expansion of a material of the insert causes the insert to contract to a first perimeter, inserting the insert at the reduced temperature into the hole, and permitting the temperature of the insert to increase from the reduced temperature to an operational temperature. At the operational temperature, the insert expands to a second perimeter so that the insert is retained within the composite material due to an interference between the insert and the composite material. The interference transfers a structural load from the insert to the composite material and results in damage to the composite material if the insert is dislodged at the operational temperature.

An exterior body panel assembly having a Class A painted surface, mold-in color or non-Class A surface, and process of infrared welding components of the assembly. Panels of the assembly are placed on a nesting structure and the inside half of the structures are brought together with the other for a fit check. Panels are separated and an infrared heating fixture then heats the various areas to be heated on the panels. The areas on the panels are heated depending on the thicknesses of the parts at each area and surface geometries to be welded. The parts are immediately clamped back together under pressure for joining and cooling of the joined surfaces in the clamped arrangement.

A liftgate assembly having finished show surfaces, and process of manufacturing same. The liftgate assembly includes local reinforcements that are overmolded to first reinforcements, and the first reinforcements are infrared welding to a first panel. Second and third reinforcements are also infrared welded to the first panel. To infrared weld the respective reinforcements to the first panel in predetermined locations with respect to the first panel, nesting structures are provided to hold the respective reinforcements and first panel. At least one infrared heating fixture heats various predetermined surfaces on the reinforcements and first panel, and the parts are then pressed together for joining the predetermined surfaces of the respective parts together. The process is repeated, if needed, until all of the reinforcements are infrared welded to the first panel. Outer panels are bonded to the second and third reinforcements.