Abstract: A dispensing system for dispensing a material to a deposition point, the dispensing system including: a nozzle configured to dispense the material; a doser in fluid communication with the nozzle, the doser configured to control flow of the material to the nozzle; and a material conditioning assembly in fluid communication with the nozzle and configured to decrease viscosity of the material. The material conditioning assembly including: a conditioning chamber configured to receive the material therein; a drive member movable within the conditioning chamber to apply shear stress to the material within the conditioning chamber; and an actuator configured to move the drive member.

Abstract: A one-step induction welding assembly configuration for a battery enclosure includes a tray constructed of a constructed of thermoplastic composite material. The tray is part of the battery enclosure. The one-step induction welding assembly configuration also includes a cooling component constructed of one of the following: thermoplastic composite material and metal, where the cooling component is joined to the tray at a joining interface, and the cooling component is part of the battery enclosure. The one-step induction welding assembly configuration also includes a plurality of induction coils that are energized to create an electromagnetic field that generates heat and joins the tray and the cooling component together at the joining interface, a layer of electrically insulating material disposed directly underneath the plurality of induction coils, and a die that exerts a clamping force against the tray of the battery enclosure.

Abstract: A system for transporting a non-Newtonian material. The system includes a storage container configured to store the non-Newtonian material and a dispensing system configured to dispense the non-Newtonian material. A conduit connects the storage container to the dispensing system. The conduit is configured to transport the non-Newtonian material from the storage container to the dispensing system. A pump is configured to pump the non-Newtonian material out of the storage container and through the conduit to the dispensing system. A hanger is configured to support the conduit from a support structure. An acoustic wave generator is along the conduit configured to impart acoustical shear agitation to the non-Newtonian material to reduce viscosity of the non-Newtonian material.

Abstract: A thermoplastic composite elongate extrudate having a thermoplastic polymer matrix material with a plurality of elongate thermoplastic liquid crystal polymer fibrils generally aligned with the direction of extrusion. A method of making a thermoplastic composite includes mixing a thermoplastic polymer matrix material and a thermoplastic liquid crystal polymer, where the viscosity of the thermoplastic polymer matrix material is sufficiently greater than the viscosity of the thermoplastic liquid crystal polymer, and extruding the mixture to create a composite elongate extrudate comprising a thermoplastic polymer matrix material with a plurality of elongate thermoplastic liquid crystal polymer fibrils generally aligned with the direction of extrusion.

Abstract: A reconditioning device includes: a first shearing plate; a second shearing plate; and a housing. The housing includes: a first member configured to hold the first shearing plate and comprising an input for receiving a material; a second member connected to the first member to form an inner cavity, a portion of the inner cavity is located in a gap between the first shearing plate and the second shearing plate; and an output member connected to a pipeline of a production applicator and configured to output the material subsequent to shearing. The shaft extends through the second member, is connected to the second shearing plate, and is configured to be rotated to shear the material disposed in the gap between the first shearing plate and the second shearing plate.

Abstract: A dispensing system for dispensing a material to a deposition point, the dispensing system including: a nozzle configured to dispense the material; a doser in fluid communication with the nozzle, the doser configured to control flow of the material to the nozzle; and a material conditioning assembly in fluid communication with the nozzle and configured to decrease viscosity of the material. The material conditioning assembly including: a conditioning chamber configured to receive the material therein; a drive member movable within the conditioning chamber to apply shear stress to the material within the conditioning chamber; and an actuator configured to move the drive member.

Abstract: A system for transporting a non-Newtonian material. The system includes a storage container configured to store the non-Newtonian material and a dispensing system configured to dispense the non-Newtonian material. A conduit connects the storage container to the dispensing system. The conduit is configured to transport the non-Newtonian material from the storage container to the dispensing system. A pump is configured to pump the non-Newtonian material out of the storage container and through the conduit to the dispensing system. A hanger is configured to support the conduit from a support structure. An acoustic wave generator is along the conduit configured to impart acoustical shear agitation to the non-Newtonian material to reduce viscosity of the non-Newtonian material.

Abstract: A reconditioning device includes: a first shearing plate; a second shearing plate; and a housing. The housing includes: a first member configured to hold the first shearing plate and comprising an input for receiving a material; a second member connected to the first member to form an inner cavity, a portion of the inner cavity is located in a gap between the first shearing plate and the second shearing plate; and an output member connected to a pipeline of a production applicator and configured to output the material subsequent to shearing. The shaft extends through the second member, is connected to the second shearing plate, and is configured to be rotated to shear the material disposed in the gap between the first shearing plate and the second shearing plate.

Abstract: A composite panel comprises a first skin and a second skin. A core is arranged between and attached to the first skin and the second skin. The core includes Z zones that are 3D printed using a thermoplastic material. Each of the Z zones abuts and is connected to another one of the Z zones. Each of the Z zones has one of D densities and at least one of the Z zones had a different density that another one of the Z zones. Z and D are integers greater than one.

Abstract: A fused filament deposition head is employed for depositing filament materials on workpieces to join the workpieces together. The workpieces can be of an automotive application, aerospace application, or something else. The fused filament deposition head, in an example, has a feed end, a dispensing end, and a heater. The feed end introduces more than one filament in the fused filament deposition head, as demanded in the larger application. The dispensing end delivers materials of the filaments to the underlying workpieces. The materials are delivered together. The heater serves to heat the filaments as they travel through the fused filament deposition head. The filaments can include a filament having a core portion of liquid-crystal polymer material.

Abstract: A composite fusion filament is disclosed that includes a polymer encasement and one or more mesogenic reinforcement bodies contained within the polymer encasement. The polymer encasement is comprised of a thermoplastic polymer, which has a melting temperature, and each of the one or more mesogenic reinforcement bodies is comprised of a thermotropic liquid crystal polymer, which has a clearing temperature. The melting temperature of the thermoplastic polymer included in the polymer encasement is less than the clearing temperature of the thermotropic liquid crystal polymer included in the one or more mesogenic reinforcement bodies. Additionally, the thermotropic liquid crystal polymer of each mesogenic reinforcement body has a plurality of organized crystalline fibrils that are aligned lengthwise along a longitudinal axis of the polymer encasement. A method of using the composite fusion filament to form a bond with a substrate that includes a thermoplastic polymer is also disclosed.

Abstract: A method of joining workpieces includes the steps of bringing a first workpiece and a second workpiece together, induction heating a susceptor material, and pressing the workpieces together. Each workpiece may include a thermoplastic material, and the workpieces are brought together at a joint interface so that a protrusion of the first workpiece is aligned with a receptacle of the second workpiece. The susceptor material is in contact with the thermoplastic material of the first workpiece during heating such that the thermoplastic material of the first workpiece softens. The step of pressing is performed while the thermoplastic material of the first workpiece is softened, thereby reshaping the first workpiece where the susceptor material is in contact with the thermoplastic material of the first workpiece. The protrusion is deformed to form an interlock with the receptacle at the joint interface.

Abstract: A method of joining a first workpiece substrate and a second workpiece substrate is disclosed in which a local mold tool is positioned into contact with the first workpiece substrate and the second workpiece substrate. The local mold tool defines a mold cavity and encloses an edge portion of the first workpiece substrate and an edge portion of the second workpiece substrate such that the edge portion of the first workpiece substrate and the edge portion of the second workpiece substrate are contained within the mold cavity. Once the local mold tool is positioned, a liquid polymer molding compound is injected into the mold cavity. The liquid polymer molding compound is hardened in the mold cavity into a polymer joint that adheres the edge portion of the first workpiece substrate and the edge portion of the second workpiece substrate together.

Abstract: A fused filament deposition head is employed for depositing filament materials on workpieces to join the workpieces together. The workpieces can be of an automotive application, aerospace application, or something else. The fused filament deposition head, in an example, has a feed end, a dispensing end, and a heater. The feed end introduces more than one filament in the fused filament deposition head, as demanded in the larger application. The dispensing end delivers materials of the filaments to the underlying workpieces. The materials are delivered together. The heater serves to heat the filaments as they travel through the fused filament deposition head. The filaments can include a filament having a core portion of liquid-crystal polymer material.

Abstract: A method of joining workpieces includes the steps of bringing a first workpiece and a second workpiece together, induction heating a susceptor material, and pressing the workpieces together. Each workpiece may include a thermoplastic material, and the workpieces are brought together at a joint interface so that a protrusion of the first workpiece is aligned with a receptacle of the second workpiece. The susceptor material is in contact with the thermoplastic material of the first workpiece during heating such that the thermoplastic material of the first workpiece softens. The step of pressing is performed while the thermoplastic material of the first workpiece is softened, thereby reshaping the first workpiece where the susceptor material is in contact with the thermoplastic material of the first workpiece. The protrusion is deformed to form an interlock with the receptacle at the joint interface.

Abstract: A composite fusion filament is disclosed that includes a polymer encasement and one or more mesogenic reinforcement bodies contained within the polymer encasement. The polymer encasement is comprised of a thermoplastic polymer, which has a melting temperature, and each of the one or more mesogenic reinforcement bodies is comprised of a thermotropic liquid crystal polymer, which has a clearing temperature. The melting temperature of the thermoplastic polymer included in the polymer encasement is less than the clearing temperature of the thermotropic liquid crystal polymer included in the one or more mesogenic reinforcement bodies. Additionally, the thermotropic liquid crystal polymer of each mesogenic reinforcement body has a plurality of organized crystalline fibrils that are aligned lengthwise along a longitudinal axis of the polymer encasement. A method of using the composite fusion filament to form a bond with a substrate that includes a thermoplastic polymer is also disclosed.

Abstract: A method or apparatus for joining a first component to a second component with an amalgamation plate includes heating the first component, the second component, the amalgamation plate, or combinations thereof, with either a joining tool or a heating element. The components are attached to the amalgamation plate with the joining tool, such that the first component, amalgamation plate, and the second component are fixedly attached to one another, and the amalgamation plate may be substantially surrounded by the first component and the second component, such that it is hidden from exposure. Portions of the amalgamation plate may be embedded into the components via rotation and/or linear force. A portion of the amalgamation plate may be recessed within the joining tool or an anvil before attaching the amalgamation plate to the either component.

Abstract: A functionalized adhesive and systems and methods employing the same are disclosed. The functionalized adhesive is configured to form an adhesive joint between a first substrate and a second substrate. The functionalized adhesive comprises a neat adhesive selected to have a bonding strength above a predetermined bonding threshold and a filler selectively dispersed within the neat adhesive. The filler is selected to modify electrical properties of the neat adhesive such that the functionalized adhesive is electrically conductive with a tailored resistivity and such that a resistance of the adhesive joint is greater than a resistance of the first substrate and the second substrate.

Abstract: Systems and methods are provided for thermal control using vascular channels. Vascular channels are incorporated in a network within a component. The component is a part of a manufactured environment configured for occupants. A fluid circuit is connected with the vascular channels and circulates a fluid through the component to alter a thermal state of the component.

Abstract: A combined composite and metal energy absorber includes a composite structure and a first metallic tube with a first section and a second section, the first section being joined to the composite structure. The composite structure and the first metallic tube have a tailored crush profile to avoid premature crushing of any of the composite structure and the first metallic tube.