Patent ID: 8741091
Filing Date: 2014-06-03
Classification: B29C,C09J,Y10T

Abstract:
1. A method for fabrication of a composite structure, comprising: (a) providing a first composite part having a first surface and a second composite part having a second surface, said first composite part and said second composite part having a common thermoplastic matrix component; (b) juxtaposing the first surface and the second surface to define a weldment area therebetween, at which the first composite part and the second composite part are to be joined; (c) providing an insert, the insert comprising (1) a film portion having a thickness T of about zero point zero three zero (0.030) inches, said film portion comprising said common thermoplastic matrix component, and (2) a resistance heating element; (d) placing the insert between the first surface and the second surface; (e) applying a selected electric current for a first selected time to said resistance heating element, to preheat said insert to at least a glass transition temperature, and then applying a selected electric current in a pulsating on-off manner to said resistance heating element, to further heat said insert and said first surface and said second surface; (f) during at least a portion of said selected time, applying a low fusion pressure to the first composite part and the second composite part to urge said first surface toward said second surface, and wherein said thermoplastic matrix in said film portion bonds with a thermoplastic matrix in or adjacent said first surface and in or adjacent said second surface to form said composite structure; (g) terminating application of said electric current; (h) applying a high fusion pressure between the first composite part and the second composite part while allowing the composite structure to cool.