Methods for ultrasonic welding of thermoplastic polymer workpieces and assemblies made therefrom are provided. The method may comprise disposing a first region of a first thermoplastic polymer workpiece and a second region of a second thermoplastic polymer workpiece between an ultrasonic horn and an anvil of an ultrasonic welding device. The first workpiece has a preformed deformation and at least one of the first and/or second workpieces has an adhesive precursor applied thereto. The ultrasonic horn or anvil seats within the preformed deformation. Ultrasonic energy is applied from the ultrasonic horn to create a weld nugget between the first and second workpieces. The assembly thus formed has a green strength sufficient to be further processed immediately. The methods provide a robust weld joint with controlled adhesive bondline thickness.

A fiber preform for use in a resin transfer molding or liquid composite molding process and process of making the same are provided. The preform includes a substrate, a fiber bundle arranged on the substrate in a predetermined pattern and attached to the substrate by a plurality of stitches of a thread. The fiber preform is capable of being pre-formed into a three-dimensional shape. The fiber preform along with a sheet of preformed thermoset resin that impregnates at least a portion of the fiber preform forms a composite material. The fiber preform reinforces areas of stress concentration of a core to form a vehicle component.

The present disclosure provides a polymeric membrane. The polymeric membrane includes a first thermoplastic elastomer layer. The thermoplastic elastomer layer includes a filler component that is at least about 30 wt % of the thermoplastic elastomer layer. The polymeric membrane can further include an optional second thermoplastic elastomer layer in contact with the first polyolefin layer.

A repulpable insulated container assembly having a container formed of paper such as corrugated cardboard or varying paper materials and defining an interior; and a repulpable insert placed within the interior of the container and formed of a first paper layer; and a paper fiber pad coupled to the first paper layer.

In a method for producing a backrest rear panel from at least one organic sheet, a plurality of reinforcing beads and a frame-shaped bead, which circles the reinforcing beads, are formed in at least one organic sheet. In a molding tool, a rib structure is formed in the circling frame-shaped bead on the rear of the backrest rear panel in such a manner that a rib structure closes flush with the rear of the backrest rear panel, with the result that an even surface is formed on the rear of the backrest rear panel. A bonded connection is formed between the organic sheet and rib structure with the result that a one-piece component is formed.

A method of manufacturing a fiber-reinforced resin material, includes preparing a kneaded material by melting a thermoplastic resin and kneading the molten thermoplastic resin with reinforcing fibers; preparing a reinforcing fiber-impregnated material including a supercritical fluid by accommodating the kneaded material in a sealed space and supplying the supercritical fluid into the sealed space such that the molten thermoplastic resin is impregnated into the reinforcing fibers included in the kneaded material; and manufacturing the fiber-reinforced resin material by extracting the reinforcing fiber-impregnated material from the sealed space and leaving the reinforcing fiber-impregnated material to stand in a reduced-pressure atmosphere such that the supercritical fluid foams.

A thermoplastic surfacer for providing lightning strike protection to a composite component of an aircraft, methods of manufacturing the surfacer, and methods of applying the surfacer to a composite part. The thermoplastic surfacer includes a broadgood having an amorphous thermoplastic resin, one or more fillers embedded into the broadgood, and a lightning strike protection mesh or foil embedded into the broadgood. When applying the surfacer to a composite part of an aircraft, the method includes draping the surfacer on an at least partially unconsolidated composite part, consolidating the at least partially unconsolidated composite part by heating the part to a temperature at or above a melt temperature of a resins used in the part and in the surfacer, and filling at least one surface defect in the consolidated part using the amorphous thermoplastic polymer resin and milled fibers provided in the thermoplastic surfacer.

A manufacturing method of a halogen-free flame-retardant thermoplastic braided fiber reinforced polymer composite board, comprising steps of: preparing a recycled material containing a halogen-free flame-retardant thermoplastic braided fiber reinforced polymer composite; adding a polymer base material to the recycled material to form a core layer material and extruding the core layer material with a low shear extruder; hot pressing the core layer material by rollers to obtain a recycled fiber core layer; preparing a reinforcement layer containing a fiber material or a fabric with pores; and stacking and hot pressing the recycled fiber core layer and the reinforcement layer.

The invention describes an extrudable coating composition including a coating thermoplastic polymer and particles, wherein the particles are made from a particle material that has a modulus of compression from 0.1 to 100 MPa. The invention further describes a coating on at least a part of the surface of an article, the coating including a coating thermoplastic polymer and particles, wherein the particles are made from a particle material that has a modulus of compression from 0.1 to 100 MPa and that at least a part of the particles protrude from the surface of the coating. The invention also describes a coated article, in particular an imitation branch, a method of coating an article, and the use of particles made from a particle material with a compression modulus of 0.1 to 100 MPa in a coating composition for the coating of articles.

A repulpable insulated container assembly having a container formed of paper such as corrugated cardboard or varying paper materials and defining an interior; and a repulpable insert placed within the interior of the container and formed of a first paper layer; and a paper fiber pad coupled to the first paper layer.