Abstract: A method for joining functional components with at least a thermoplastic components to thermosetting composites with at least some thermoplastic surface. The thermosetting composite has a functional thermoplastic surface layer attached by a process of selection of a compatible thermoplastic, heating the combined materials to allow migration of uncured thermosetting polymer into the thermoplastic polymer, then cooling the combined materials to provide a strongly attached thermoplastic surface. The thermosetting composite component may have a polymeric material coating. The present invention subsequently relates to the joining of the functional component and thermosetting polymer composite components, using high-speed oscillating relative displacement or high-speed continuous relative displacement.

Abstract: A method of creating a functional utility-surface on a thermoset composite component, including the steps of: fixing the position of a cured thermoset polymer composite component, the thermoset polymer composite component having a thermoplastic polymer surface layer attached to at least a portion of one surface thereof, the thermoset polymer composite component being fixed in position to allow access to the thermoplastic polymer surface layer; and shaping the thermoplastic polymer surface to form a functional utility-surface.

Abstract: A method and apparatus is disclosed for joining of composites with thermoplastic surfaces. The process includes the location of the said components within a load bearing frame, and bringing the thermoplastic surfaces to be joined into contact. Pressure application devices, in the form of fluid filled bladders, are also located within the frame, and are located such that pressure is applied evenly to said thermoplastic surfaces. Where components have a high level of curve or twist, form blocks that have the approximate shape of the component surface are located between the frame and bladders. Pressure and heat are applied to the joint area, and heat removed while the joint area is maintained under some pressure. A feature of the present invention is the option of using opposing pressure application devices, reducing the need for substantial tooling in order to maintain component location accuracy.

Abstract: An apparatus for welding together polymer composite components to form a composite frame, the apparatus including: a load bearing apparatus; a plurality of location elements for respectively locating at least one component of the composite frame to be assembled, each location element being connected to the load bearing apparatus; at least one of said location elements being a moveable location element, the position of said location element being moveable with respect to said load bearing apparatus; guides for the precise movement of said locating elements to position the composite components into a series of joints which form the composite frame; at lease one actuation means for the at least one moveable location element, the actuation means being attached to the load bearing apparatus and to the at least one moveable location element; at least one motion limiting apparatus applied to the at least one moveable location element, the motion limiting apparatus being either a means of control of the force applied

Abstract: A method of precision surface re-profiling of a composite polymeric component comprising a region capable of being re-profiled, comprising the steps of locating the polymeric composite component with a formable surface relative to a supporting fixture, the thickness of component comprising the formable surface being greater than the desired final thickness in a region to be re-profiled, moving a forming head into position into contact with the formable surface of the composite component with the aid of precision location or measurement sensors, causing the formable surface of the component to flow under the tool and creating a precisely defined local thickness or profile of component under the forming tool, and moving the forming head along the region of the component to be re-profiled, while maintaining the forming tool at a predetermined height profile or while leaving the re-profiled component with a predetermined thickness profile.

Abstract: A process for assembling a composite component with a thermoplastic surface into or around a second component, the process including selecting a first component with a thermoplastic surface and a second component that, when assembled with the first component has at least some points of contact, shaping where necessary at least one component in the joint area, and pressing the components together to achieve relative immobility between the components. A second process involves the selection of a third thermoplastic component to be assembled with the first two components with at least some points of contact with the first and second components are achieved, shaping where necessary, and assembling such that relative immobility is achieved between all three components. In both processes, the joint area is then heated to allow the thermoplastic to flow and preferably weld the assembled components together.