METHODS FOR JOINING A FIRST THERMOPLASTIC SUBSTRATE WITH A SECOND THERMOPLASTIC SUBSTRATE

A method for joining a first thermoplastic substrate and a second thermoplastic substrate, each including a polyaryletherketone material having a first melting temperature. The method includes co-consolidating a first semicrystalline thermoplastic film with the first thermoplastic substrate to yield a first co-consolidated structure. The first semicrystalline thermoplastic film defines a first bonding surface of the first co-consolidated structure and includes a polyaryletherketone material having a second melting temperature that is less than the first melting temperature. The method further includes co-consolidating a second semicrystalline thermoplastic film with the second thermoplastic substrate to yield a second co-consolidated structure. The second semicrystalline thermoplastic film defines a second bonding surface of the second co-consolidated structure and includes a polyaryletherketone material having a third melting temperature that is less than the first melting temperature. The method further includes fusing the first bonding surface to the second bonding surface. The method yields a stacked structure.

FIELD

This application relates to the joining of composite parts and, more specifically, to joining two or more thermoplastic parts by film fusion and the resulting stacked structures therefrom.

BACKGROUND

Joining thermoplastic to thermoplastic composites typically requires the use of fasteners. The inert nature of thermoplastic polymers, meaning the nonreactive nature of the thermoplastic polymer within composite material, makes joining without fasteners difficult. Joining without fasteners typically requires the composite surface to be subjected to extensive treatment prior to adhesive bonding (e.g., by plasma etching or by aggressive sanding). These treatments are both costly and time consuming. Another challenge with joining thermoplastic to thermoplastic composites is finding joining materials that are compatible at the molecular level with the thermoplastic polymer in the composite material. Finally, differences in the melting temperatures may result in compromising the mechanical properties of the composite parts if the joining temperature surpasses the melting temperature of the composite parts.

Film joining processes have been explored in the past. However, the joining films are typically amorphous polymers, which are susceptible to solvents and lack creep resistance under load.

Accordingly, those skilled in the art continue with research and development efforts in the field of joining two or more parts having thermoplastic material.

SUMMARY

Disclosed are methods for joining a first thermoplastic substrate with a second thermoplastic substrate. The first thermoplastic substrate and the second thermoplastic substrate include a polyaryletherketone material having a first melting temperature.

In one example, the disclosed method includes co-consolidating a first semicrystalline thermoplastic film with the first thermoplastic substrate to yield a first co-consolidated structure. The first semicrystalline thermoplastic film includes a polyaryletherketone material having a second melting temperature. The second melting temperature is less than the first melting temperature. The first semicrystalline thermoplastic film defines a first bonding surface of the first co-consolidated structure. The method further includes co-consolidating a second semicrystalline thermoplastic film with the second thermoplastic substrate to yield a second co-consolidated structure. The second semicrystalline thermoplastic film includes a polyaryletherketone material having a third melting temperature that is less than the first melting temperature. The second semicrystalline thermoplastic film defines a second bonding surface of the second co-consolidated structure. The method further includes fusing the first bonding surface of the first co-consolidated structure to the second bonding surface of the second co-consolidated structure.

Also disclosed is a stacked structure.

In one example, the stacked structure includes a first co-consolidated structure. The first co-consolidated structure has a first thermoplastic substrate comprising a polyaryletherketone material. The first thermoplastic substrate has a first melting temperature. The first co-consolidated structure further includes a first semicrystalline thermoplastic film comprising a polyaryletherketone material. The first semicrystalline thermoplastic film has a second melting temperature that is less than the first melting temperature. The first semicrystalline thermoplastic film defines a first bonding surface of the first co-consolidated structure. The stacked structure further includes a second co-consolidated structure. The second co-consolidated structure has a second thermoplastic substrate comprising a polyaryletherketone material. The second thermoplastic substrate has a first melting temperature. The second co-consolidated structure further includes a second semicrystalline thermoplastic film comprising a polyaryletherketone material. The second semicrystalline thermoplastic film has a third melting temperature that is less than the first melting temperature. The second semicrystalline thermoplastic film defines a second bonding surface of the second co-consolidated structure.

Other examples of the disclosed methods for joining a first thermoplastic substrate with a second thermoplastic substrate will become apparent from the following detailed description, the accompanying drawings and the appended claims.

DETAILED DESCRIPTION

Disclosed is a method for joining a first thermoplastic substrate with a second thermoplastic substrate via film fusion with an interlayer polymer film to yield a stacked structure. The interlayer polymer film has a lower transition temperature such that the interlayer polymer film can diffuse and join the composite substrates before deconsolidation (softening/melting) of each composite substrate. This method allows for joining thermoplastic substrates and facilitating molecular diffusion without the use of fasteners. Further, the method protects the material properties such that they are not sacrificed during the joining process.

In one example, the interlayer polymer film is a semi-crystalline film belonging to the family of polyaryletherketone (PAEK) polymers. The joining processing window was determined by mechanical testing of pull off coupons joined at various conditions. The joining robustness was validated using double lap shear and double cantilever beam tests. This joining process then was demonstrated on a thermoplastic skin stringer assembly. Without sophisticated and expensive tooling requirements and with minimum surface preparation, the joining method yields potential for manufacturing structural composite components assemblies at lower costs.

Disclosed is a method100, seeFIG. 1, for joining a first thermoplastic substrate210with a second thermoplastic substrate220, seeFIG. 2A, to yield a stacked structure275, seeFIG. 2C. In one or more examples, the first thermoplastic substrate210and the second thermoplastic substrate220have substantially the same melting temperature. In one example, the first thermoplastic substrate210comprises a polyaryletherketone material having a first melting temperature TM1. In one or more examples, the first thermoplastic substrate210comprises polyether ketone ketone. In another example, the first thermoplastic substrate210comprises polyether ether ketone. In one or more examples, the first thermoplastic substrate210comprises a polyaryletherketone blend.

In one or more examples, the second thermoplastic substrate220comprises a polyaryletherketone material having a first melting temperature TM1. In one or more examples, the second thermoplastic substrate220comprises polyether ketone ketone. In one example, the second thermoplastic substrate220comprises polyether ether ketone. In one or more examples, the second thermoplastic substrate220comprises a polyaryletherketone blend. In another example, the first thermoplastic substrate210and the second thermoplastic substrate220comprise the same polyaryletherketone material. In yet another example, the first thermoplastic substrate210and the second thermoplastic substrate220comprise different polyaryletherketone materials.

FIG. 2Aillustrates an example of the first thermoplastic substrate210and the second thermoplastic substrate220prior to joining. In one or more examples, the method100comprises co-consolidating110,FIG. 1, a first semicrystalline thermoplastic film215with the first thermoplastic substrate210to yield a first co-consolidated structure217. In one example, the first semicrystalline thermoplastic film215comprises a polyaryletherketone material having a second melting temperature TM2. In another example, the second melting temperature TM2is less than the first melting temperature TM1. In one or more examples, the first semicrystalline thermoplastic film215comprises polyether ketone ketone. In one or more examples, the first semicrystalline thermoplastic film215comprises polyether ether ketone. In yet another, the first semicrystalline thermoplastic film215comprises a polyaryletherketone blend.

In one or more examples, the first semicrystalline thermoplastic film215defines a first bonding surface219of the first co-consolidated structure217. In one example, the first co-consolidated structure217has a first co-consolidating temperature T1. The first co-consolidating temperature T1defines the temperature upon which co-consolidating110occurs along the first bonding surface219to yield the first co-consolidated structure217. In one or more examples, the first co-consolidating temperature T1is greater than the first melting temperature TM1. In another example, the co-consolidating110the first semicrystalline thermoplastic film215with the first thermoplastic substrate210is performed at a first co-consolidation temperature T1between about 300° C. and about 421° C.

In one or more examples, the method100comprises co-consolidating120a second semicrystalline thermoplastic film225with the second thermoplastic substrate220to yield a second co-consolidated structure227, seeFIG. 2B. In one or more examples, the second semicrystalline thermoplastic film225comprises a polyaryletherketone material having a third melting temperature TM3. In one or more examples, the third melting temperature TM3is less than the first melting temperature TM1. In one or more examples, the third melting temperature TM3is substantially the same as the second melting temperature TM2.

In one or more examples, the second semicrystalline thermoplastic film225comprises polyether ketone ketone. In one or more examples, the second semicrystalline thermoplastic film225comprises polyether ether ketone. In one or more examples, the second semicrystalline thermoplastic film225comprises a polyaryletherketone blend. In one or more examples, the first semicrystalline thermoplastic film215and the second semicrystalline thermoplastic film225comprise the same polyaryletherketone material.

Referring toFIG. 2A, in one or more examples, the second semicrystalline thermoplastic film225defines a second bonding surface229of the second co-consolidated structure227. In or more examples, the second co-consolidated structure227has a second co-consolidating temperature T2. The second co-consolidating temperature T2defines the temperature upon which co-consolidating120occurs along the second bonding surface229to yield the second co-consolidated structure227. In one or more examples, the second co-consolidating temperature T2is greater than the first melting temperature TM1. In another example, the second co-consolidating temperature T2is substantially the same as the first co-consolidating temperature T1. In one example, the second co-consolidating temperature T2is less than the first co-consolidating temperature T1. In another example, the second co-consolidating temperature T2is greater than the first co-consolidating temperature T1. In yet another example, the co-consolidating120the second semicrystalline thermoplastic film225with the second thermoplastic substrate220is performed at second co-consolidating temperature T2between about 300° C. and about 421° C.

As illustrated inFIG. 2A, the first thermoplastic substrate210and the second thermoplastic substrate220have a first melting temperature TM1, the first semicrystalline thermoplastic film215has a second melting temperature TM2, and the second semicrystalline thermoplastic film225has a third melting temperature TM3. In one or more examples, the difference between the first melting temperature TM1and the second melting temperature TM2is at least 20° C. In one or more examples, the difference between the first melting temperature TM1and the second melting temperature TM2is at least 25° C. In one or more examples, the difference between the first melting temperature TM1and the second melting temperature TM2is at least 30° C. In one or more examples, the difference between the first melting temperature TM1and the second melting temperature TM2is at least 35° C. In one or more examples, the difference between the first melting temperature TM1and the second melting temperature TM2is at least 40° C. In one or more examples, the difference between the first melting temperature TM1and the second melting temperature TM2is greater than 40° C.

As illustrated inFIG. 2A, the first thermoplastic substrate210and the second thermoplastic substrate220have a first melting temperature TM1, the first semicrystalline thermoplastic film215has a second melting temperature TM2, and the second semicrystalline thermoplastic film225has a third melting temperature TM3. In one or more examples, the difference between the first melting temperature TM1and the third melting temperature TM3is at least 10° C. In one or more examples, the difference between the first melting temperature TM1and the third melting temperature TM3is at least 15° C. In another example, the difference between the first melting temperature TM1and the third melting temperature TM3is at least 20° C. In another example, the difference between the first melting temperature TM1and the third melting temperature TM3is at least 25° C. In another example, the difference between the first melting temperature TM1and the third melting temperature TM3is at least 30° C. In another example, the difference between the first melting temperature TM1and the third melting temperature TM3is at least 35° C. In another example, the difference between the first melting temperature TM1and the third melting temperature TM3is at least 40° C. In yet another example, the difference between the first melting temperature TM1and the third melting temperature TM3is greater than 40° C.

Referring toFIG. 1, in one or more examples, the method100comprises fusing150the first bonding surface219of the first co-consolidated structure217to the second bonding surface229of the second co-consolidated structure227to yield a stacked structure275, seeFIG. 2C. In one or more examples, the first semicrystalline thermoplastic film215of the first bonding surface219is miscible with the second semicrystalline thermoplastic film225of the second bonding surface229. In one or more examples, the fusing150comprises heating140the first co-consolidated structure217and the second co-consolidated structure227. In one or more examples, the heating140comprises any suitable means of heating, including conduction heating, convection heating, induction heating, and the like.

Referring toFIG. 1, in one or more examples, the heating140comprises heating140the first co-consolidated structure217and the second co-consolidated structure227to a joining temperature for joining the entire assembly, wherein the joining temperature is greater than the second melting temperature TM2and the third melting temperature TM3. In one or more examples, the joining temperature is less than the first melting temperature TM1. In another example, the fusing150is performed at a temperature between about 260° C. and about 350° C. In yet another example, the fusing150is performed at a temperature between about 299° C. and about 350° C.

Referring toFIG. 1, in one or more examples, the fusing150further comprises pressing160the first bonding surface219of the first co-consolidated structure217into engagement with the second bonding surface229of the second co-consolidated structure227. In one or more examples, the fusing150comprises applying pressure to the first thermoplastic substrate210and/or to the second thermoplastic substrate220. In one or more examples, the fusing150comprises applying pressure with an inflatable bladder. In one or more examples, the fusing150comprises applying pressure with the inflatable bladder at about 14 psi to about 60 psi. In one or more examples, the fusing150comprises applying pressure via any suitable means including vacuum pressure, a heated press, an autoclave, a pressure vessel, or the like.

FIG. 2Billustrates an example of the first co-consolidated structure217and the second co-consolidated structure227having a third semicrystalline thermoplastic film230disposed between. Referring toFIG. 1, in one or more examples, the method100comprises, prior to the fusing150, positioning130a third semicrystalline thermoplastic film230between and in contact with both the first bonding surface219of the first co-consolidated structure217and the second bonding surface229of the second co-consolidated structure227. In one or more examples, the third semicrystalline thermoplastic film230comprises a polyaryletherketone material having a fourth melting temperature TM4.

In one or more examples, the third semicrystalline thermoplastic film230comprises polyether ketone ketone. In one or more examples, the third semicrystalline thermoplastic film230comprises polyether ether ketone. In one or more examples, the third semicrystalline thermoplastic film230comprises a polyaryletherketone blend. In one or more examples, the third semicrystalline thermoplastic film230comprises a blend of polyether ketone ketone and polyether ether ketone. In one or more examples, the fourth melting temperature TM4is substantially the same as the second melting temperature TM2and the third melting temperature TM3.

The semicrystalline nature of the first semicrystalline thermoplastic film, the second semicrystalline thermoplastic film, and the third semicrystalline thermoplastic film allows for each respective film to sustain various environmental conditions. The semicrystalline nature further provides necessary strength and solvent resistance for each layer. In one or more examples, the degree of crystallinity is the same in each respective film. In one or more examples, the degree of crystallinity is different in one or more of each film. In one or more examples, the degree of crystallinity in the first semicrystalline thermoplastic film, the second semicrystalline thermoplastic film, and the third semicrystalline thermoplastic film ranges from about 5% crystalline to about 35% crystalline. In one or more examples, the degree of crystallinity in the first semicrystalline thermoplastic film, the second semicrystalline thermoplastic film, and the third semicrystalline thermoplastic film ranges from about 10% crystalline to about 30% crystalline. In one or more examples, the degree of crystallinity in the first semicrystalline thermoplastic film, the second semicrystalline thermoplastic film, and the third semicrystalline thermoplastic film ranges from about 15% crystalline to about 30% crystalline.

Referring toFIG. 3andFIG. 4, the disclosed method100and resulting stacked structure275will be used in the context of aircraft manufacturing and service including material procurement (block1106), production, component and subassembly manufacturing (block1108), and certification and delivery (block1112) of aircraft1102.

Examples of the subject matter, disclosed herein may be described in the context of aircraft manufacturing and service method1100as shown inFIG. 3and aircraft1102as shown inFIG. 4. In one or more examples, the stacked structure275comprises a stringer assembly used in aircraft manufacturing. During pre-production, illustrative method1100may include specification and design (block1104) of aircraft1102and material procurement (block1106). During production, component and subassembly manufacturing (block1108) and system integration (block1110) of aircraft1102may take place. Thereafter, aircraft1102may go through certification and delivery (block1112) to be placed in service (block1114). While in service, aircraft1102may be scheduled for routine maintenance and service (block1116). Routine maintenance and service may include modification, reconfiguration, refurbishment, etc. of one or more systems of aircraft1102.

Examples of high-level systems1120include one or more of propulsion system1124, electrical system1126, hydraulic system1128, and environmental system1130. Any number of other systems may be included. Although an aerospace example is shown, the principles disclosed herein may be applied to other industries, such as the automotive industry. Accordingly, in addition to aircraft1102, the principles disclosed herein may apply to other vehicles, e.g., land vehicles, marine vehicles, space vehicles, etc.

Apparatus(es) and method(s) shown or described herein may be employed during any one or more of the stages of the manufacturing and service method1100. For example, components or subassemblies corresponding to component and subassembly manufacturing (block1108) may be fabricated or manufactured in a manner similar to components or subassemblies produced while aircraft1102is in service (block1114). Also, one or more examples of the apparatus(es), method(s), or combination thereof may be utilized during production stages (block1108and block1110), for example, by substantially expediting assembly of or reducing the cost of aircraft1102. Similarly, one or more examples of the apparatus or method realizations, or a combination thereof, may be utilized, for example and without limitation, while aircraft1102is in service (block1114) and/or during maintenance and service (block1116).

Further, the disclosure comprise examples according to the following clauses:

Clause 1. A method (100) for joining a first thermoplastic substrate (210) with a second thermoplastic substrate (220), the first thermoplastic substrate (210) and the second thermoplastic substrate (220) both comprising a polyaryletherketone material having a first melting temperature (TM1), the method (100) comprising:

co-consolidating (110) a first semicrystalline thermoplastic film (215) with the first thermoplastic substrate (210) to yield a first co-consolidated structure (217), the first semicrystalline thermoplastic film (215) comprising a polyaryletherketone material having a second melting temperature (TM2), the second melting temperature (TM2) being less than the first melting temperature (TM1), wherein the first semicrystalline thermoplastic film (215) defines a first bonding surface (219) of the first co-consolidated structure (217);

co-consolidating (120) a second semicrystalline thermoplastic film (225) with the second thermoplastic substrate (220) to yield a second co-consolidated structure (227), the second semicrystalline thermoplastic film (225) comprising a polyaryletherketone material having a third melting temperature (TM3), the third melting temperature (TM3) being less than the first melting temperature (TM1), wherein the second semicrystalline thermoplastic film (225) defines a second bonding surface (229) of the second co-consolidated structure (227); and fusing (150) the first bonding surface (219) of the first co-consolidated structure (217) to the second bonding surface (229) of the second co-consolidated structure (227).

Clause 2. The method (100) of Clause 1 wherein the second melting temperature (TM2) and the third melting temperature (TM3) are substantially the same.

Clause 3. The method (100) of Clause 1 or Clause 2 wherein a difference between the first melting temperature (TM1) and the second melting temperature (TM2) is at least 5° C. and a difference between the first melting temperature (TM1) and the third melting temperature (TM3) is at least 20° C.

Clause 4. The method (100) of any of Clauses 1-3 wherein a difference between the first melting temperature (TM1) and the second melting temperature (TM2) is at least 10° C. and a difference between the first melting temperature (TM1) and the third melting temperature (TM3) is at least 25° C.

Clause 5. The method (100) of any of Clauses 1-4 wherein a difference between the first melting temperature (TM1) and the second melting temperature (TM2) is at least 15° C. and a difference between the first melting temperature (TM1) and the third melting temperature (TM3) is at least 30° C.

Clause 6. The method (100) of any of Clauses 1-5 wherein a difference between the first melting temperature (TM1) and the second melting temperature (TM2) is at least 20° C. and a difference between the first melting temperature (TM1) and the third melting temperature (TM3) is at least 35° C.

Clause 7. The method (100) of any of Clauses 1-6 wherein a difference between the first melting temperature (TM1) and the second melting temperature (TM2) is at least 30° C. and a difference between the first melting temperature (TM1) and the third melting temperature (TM3) is at least 40° C.

Clause 8. The method (100) of any of Clauses 1-7 wherein the fusing (150) comprises heating (140) the first co-consolidated structure (217) and the second co-consolidated structure (227).

Clause 9. The method (100) of Clause 8 wherein the heating (140) comprises heating (140) the first co-consolidated structure (217) and the second co-consolidated structure (227) to a joining temperature, wherein the joining temperature is greater than the second melting temperature (TM2) and the third melting temperature (TM3), and less than the first melting temperature (TM1).

Clause 10. The method (100) of Clause 8 or Clause 9 wherein the fusing (150) further comprises pressing (160) the first bonding surface (219) of the first co-consolidated structure (217) into engagement with the second bonding surface (229) of the second co-consolidated structure (227).

Clause 11. The method (100) of any of Clauses 8-10 wherein the heating (140) comprises conduction heating.

Clause 12. The method (100) of any of Clauses 1-11 wherein the first co-consolidated structure (217) has a first co-consolidating temperature T1.

Clause 13. The method (100) of Clause 12 wherein the first co-consolidating temperature T1is greater than the first melting temperature TM1.

Clause 14. The method (100) of Clause 12 or Clause 13 wherein the second co-consolidated structure (227) has a second co-consolidating temperature T2.

Clause 15. The method (100) of Clause 14 wherein the second co-consolidating temperature T2is greater than the first melting temperature TM1.

Clause 16. The method (100) of any of Clauses 1-15 further comprising, prior to the fusing, positioning (130) a third semicrystalline thermoplastic film (230) between and in contact with both the first bonding surface (219) of the first co-consolidated structure (217) and the second bonding surface (229) of the second co-consolidated structure (227), the third semicrystalline thermoplastic film (230) comprising a polyaryletherketone material having a fourth melting temperature (TM4).

Clause 17. The method (100) of Clause 16 wherein the fourth melting temperature (TM4) is substantially the same as the second melting temperature (TM2) and the third melting temperature (TM3).

Clause 18. The method (100) of Clause 16 or Clause 17 wherein the third semicrystalline thermoplastic film (230) comprises polyether ether ketone.

Clause 19. The method (100) of Clause 16 or Clause 17 wherein the third semicrystalline thermoplastic film (230) comprises polyether ketone ketone.

Clause 20. The method (100) of Clause 16 of Clause 17 wherein the third semicrystalline thermoplastic film (230) comprises a blend of polyether ketone ketone and polyether ether ketone.

Clause 21. The method (100) of any of Clauses 1-20 wherein the first thermoplastic substrate (210) and the second thermoplastic substrate (220) comprise polyether ether ketone.

Clause 22. The method (100) of Clause 21 wherein first semicrystalline thermoplastic film (215) and the second semicrystalline thermoplastic film (225) comprise polyether ether ketone.

Clause 23. The method (100) of any of Clauses 1-22 wherein the first thermoplastic substrate (210) and the second thermoplastic substrate (220) comprise polyether ketone ketone.

Clause 24. The method (100) of any of Clauses 1-23 wherein the co-consolidating (110) the first semicrystalline thermoplastic film (215) with the first thermoplastic substrate (210) and the co-consolidating (120) the second semicrystalline thermoplastic film (225) with the second thermoplastic substrate (220) are performed at a temperature between about 300° C. and about 420° C.

Clause 25. The method (100) of any of Clauses 1-24 wherein the fusing (150) comprises heating (140) and pressing (160).

Clause 26. The method (100) of any of Clauses 1-25 wherein the fusing (150) is performed at a temperature between about 260° C. and about 350° C.

Clause 27. The method (100) of any of Clauses 1-26 wherein the fusing (150) is performed at a temperature between about 299° C. and about 350° C.

Clause 28. The method (100) of any of Clauses 1-27 wherein the fusing (150) comprises applying pressure to at least one of the first thermoplastic substrate (210) and the second thermoplastic substrate (220).

Clause 29. The method (100) of any of Clauses 1-28 wherein the fusing (150) comprises applying pressure with a pressure vessel.

Clause 30. The method (100) of any of Clauses 1-29 wherein the fusing (150) comprises applying pressure with an inflatable bladder at about 14 psi to about 60 psi.

Clause 31. The method (100) of any of Clauses 1-30 wherein the fusing (150) comprises applying pressure with an autoclave.

Clause 32. The method (100) of any of Clauses 1-31 wherein the fusing (150) comprises applying pressure with a vacuum.

Clause 33. A method (100) for joining a first thermoplastic substrate (210) with a second thermoplastic substrate (220), the first thermoplastic substrate (210) and the second thermoplastic substrate (220) both comprising a polyaryletherketone material having a first melting temperature (TM1), the method (100) comprising:

co-consolidating (110) a first semicrystalline thermoplastic film (215) with the first thermoplastic substrate (210) to yield a first co-consolidated structure (217), the first semicrystalline thermoplastic film (215) comprising a polyaryletherketone material having a second melting temperature (TM2), the second melting temperature (TM2) being less than the first melting temperature (TM1), wherein the first semicrystalline thermoplastic film (215) defines a first bonding surface (219) of the first co-consolidated structure (217);

co-consolidating (120) a second semicrystalline thermoplastic film (225) with the second thermoplastic substrate (220) to yield a second co-consolidated structure (227), the second semicrystalline thermoplastic film (225) comprising a polyaryletherketone material having a third melting temperature (TM3), the third melting temperature (TM3) being less than the first melting temperature (TM1), wherein the second semicrystalline thermoplastic film (225) defines a second bonding surface (229) of the second co-consolidated structure (227);

positioning (130) a third semicrystalline thermoplastic film (230) between and in contact with both the first bonding surface (219) of the first co-consolidated structure (217) and the second bonding surface (229) of the second co-consolidated structure (227), the third semicrystalline thermoplastic film (230) comprising a polyaryletherketone material having a fourth melting temperature (TM4);

heating (140) the first bonding surface (219) of the first co-consolidated structure (217) and the second bonding surface (229) of the second co-consolidated structure (227); and

pressing (160) the first bonding surface (219) of the first co-consolidated structure (217) into engagement with the second bonding surface (229) of the second co-consolidated structure (227).

Clause 34. The method (100) of Clause 33 wherein a difference between the first melting temperature (TM1) and the second melting temperature (TM2) is at least 5° C. and a difference between the first melting temperature (TM1) and the third melting temperature (TM3) is at least 20° C.

Clause 35. The method (100) of Clause 33 or Clause 34 wherein a difference between the first melting temperature (TM1) and the second melting temperature (TM2) is at least 10° C. and a difference between the first melting temperature (TM1) and the third melting temperature (TM3) is at least 25° C.

Clause 36. The method (100) of any of Clauses 33-35 wherein a difference between the first melting temperature (TM1) and the second melting temperature (TM2) is at least 15° C. and a difference between the first melting temperature (TM1) and the third melting temperature (TM3) is at least 30° C.

Clause 37. The method (100) of any of Clauses 33-36 wherein a difference between the first melting temperature (TM1) and the second melting temperature (TM2) is at least 20° C. and a difference between the first melting temperature (TM1) and the third melting temperature (TM3) is at least 35° C.

Clause 38. The method (100) of any of Clauses 33-37 wherein a difference between the first melting temperature (TM1) and the second melting temperature (TM2) is at least 30° C. and a difference between the first melting temperature (TM1) and the third melting temperature (TM3) is at least 40° C.

Clause 39. The method (100) of any of Clauses 33-38 wherein the fourth melting temperature (TM4) is substantially the same as the second melting temperature (TM2) and the third melting temperature (TM3).

Clause 40. The method (100) of any of Clauses 33-39 wherein the third semicrystalline thermoplastic film (230) comprises polyether ether ketone.

Clause 41. The method (100) of any of Clauses 33-40 wherein the third semicrystalline thermoplastic film (230) comprises polyether ketone ketone.

Clause 42. The method (100) of any of Clauses 33-41 wherein the third semicrystalline thermoplastic film (230) comprises a blend of polyether ketone ketone and polyether ether ketone.

Clause 43. The method (100) of any of Clauses 33-42 wherein the first thermoplastic substrate (210) and the second thermoplastic substrate (220) comprise polyether ether ketone.

Clause 44. The method (100) of any of Clauses 33-43 wherein first semicrystalline thermoplastic film (215) and the second semicrystalline thermoplastic film (225) comprise polyether ether ketone.

Clause 45. The method (100) of any of Clauses 33-44 wherein the first thermoplastic substrate (210) and the second thermoplastic substrate (220) comprise polyether ketone ketone.

Clause 46. The method (100) of any of Clauses 33-45 wherein the co-consolidating (110) the first semicrystalline thermoplastic film (215) with the first thermoplastic substrate (210) and the co-consolidating (120) the second semicrystalline thermoplastic film (225) with the second thermoplastic substrate (220) are performed at a temperature between about 300° C. and about 420° C.

Clause 47. The method (100) of any of Clauses 33-46 wherein the first co-consolidated structure (217) has a first co-consolidating temperature T1.

Clause 48. The method (100) of Clause 47 wherein the first co-consolidating temperature T1is greater than the first melting temperature (TM1).

Clause 49. The method (100) of any of Clauses 33-48 wherein the second co-consolidated structure (227) has a second co-consolidating temperature (T2).

Clause 50. The method (100) of Clause 49 wherein the second co-consolidating temperature (T2) is greater than the first melting temperature (TM1).

Clause 51. The method (100) of any of Clauses 33-50 wherein the heating (140) is performed at a temperature between about 260° C. and about 350° C.

Clause 52. The method (100) of any of Clauses 33-51 wherein the heating (140) is performed at a temperature between about 299° C. and about 350° C.

Clause 53. The method (100) of any of Clauses 33-52 wherein the pressing (160) comprises applying pressure with a pressure vessel.

Clause 54. The method (100) of any of Clauses 33-53 wherein the pressing (160) comprises applying pressure with an inflatable bladder at about 14 psi to about 60 psi.

Clause 55. The method (100) of any of Clauses 33-54 wherein the pressing (160) comprises applying pressure with an autoclave.

Clause 56. The method (100) of any of Clauses 33-55 wherein the pressing (160) comprises applying pressure with a vacuum.

a first co-consolidated structure (217) comprising:

a first thermoplastic substrate (210) comprising a polyaryletherketone material, said first thermoplastic substrate (210) having a first melting temperature (TM1); and

a first semicrystalline thermoplastic film (215) comprising a polyaryletherketone material, said a first semicrystalline thermoplastic film (215) having a second melting temperature (TM2) that is less than the first melting temperature (TM1), wherein the first semicrystalline thermoplastic film (215) defines a first bonding surface (219) of the first co-consolidated structure (217); and

a second thermoplastic substrate (220) comprising a polyaryletherketone material, said second thermoplastic substrate (220) having a first melting temperature (TM1); and

a second semicrystalline thermoplastic film (225) comprising a polyaryletherketone material, said second semicrystalline thermoplastic film (225) having a third melting temperature (TM3) that is less than the first melting temperature (TM1), wherein the second semicrystalline thermoplastic film (225) defines a second bonding surface (229) of the second co-consolidated structure (227).

Clause 58. The stacked structure (275) of Clause 57 wherein the first co-consolidated structure (217) has a first co-consolidating temperature T1.

Clause 59. The stacked structure (275) of Clause 58 wherein the first co-consolidating temperature T1is greater than the first melting temperature (TM1).

Clause 60. The stacked structure (275) of any of Clauses 57-59 wherein the second co-consolidated structure (227) has a second co-consolidating temperature (T2).

Clause 61. The stacked structure (275) of Clause 60 wherein the second co-consolidating temperature (T2) is greater than the first melting temperature (TM1).

Clause 62. The stacked structure (275) of any of Clauses 57-61 wherein a difference between the first melting temperature (TM1) and the second melting temperature (TM2) is at least 5° C. and a difference between the first melting temperature (TM1) and the third melting temperature (TM3) is at least 20° C.

Clause 63. The stacked structure (275) of any of Clauses 57-62 wherein a difference between the first melting temperature (TM1) and the second melting temperature (TM2) is at least 10° C. and a difference between the first melting temperature (TM1) and the third melting temperature (TM3) is at least 25° C.

Clause 64. The stacked structure (275) of any of Clauses 57-63 wherein a difference between the first melting temperature (TM1) and the second melting temperature (TM2) is at least 15° C. and a difference between the first melting temperature (TM1) and the third melting temperature (TM3) is at least 30° C.

Clause 65. The stacked structure (275) of any of Clauses 57-64 wherein a difference between the first melting temperature (TM1) and the second melting temperature (TM2) is at least 20° C. and a difference between the first melting temperature (TM1) and the third melting temperature (TM3) is at least 35° C.

Clause 66. The stacked structure (275) of any of Clauses 57-65 wherein a difference between the first melting temperature (TM1) and the second melting temperature (TM2) is at least 30° C. and a difference between the first melting temperature (TM1) and the third melting temperature (TM3) is at least 40° C.

Clause 67. The stacked structure (275) of any of Clauses 57-66 wherein the second melting temperature (TM2) and the third melting temperature (TM3) are substantially the same.

Clause 68. The stacked structure (275) of any of Clauses 57-67 wherein the first thermoplastic substrate (210) and the second thermoplastic substrate (220) comprise polyether ether ketone.

Clause 69. The stacked structure (275) of any of Clauses 57-68 wherein first semicrystalline thermoplastic film (215) and the second semicrystalline thermoplastic film (225) comprise polyether ether ketone.

Clause 70. The stacked structure (275) of any of Clauses 57-69 wherein the first thermoplastic substrate (210) and the second thermoplastic substrate (220) comprise polyether ketone ketone.

Clause 71. The stacked structure (275) of any of Clauses 57-70 further comprising a third semicrystalline thermoplastic film (230) disposed between and in contact with both the first bonding surface (219) of the first co-consolidated structure (217) and the second bonding surface (229) of the second co-consolidated structure (227), said third semicrystalline thermoplastic film (230) comprising a polyaryletherketone material and having a fourth melting temperature (TM4).

Clause 72. The stacked structure (275) of Clause 71 wherein the fourth melting temperature (TM4) is substantially the same as the second melting temperature (TM2) and the third melting temperature (TM3).

Clause 73. The stacked structure (275) of Clause 71 or Clause 72 wherein the third semicrystalline thermoplastic film (230) comprises polyether ether ketone.

Clause 74. The stacked structure (275) of Clause 71 or Clause 72 wherein the third semicrystalline thermoplastic film (230) comprises polyether ketone ketone.

Clause 75. The stacked structure (275) of Clause 71 or Clause 72 wherein the third semicrystalline thermoplastic film (230) comprises a blend of polyether ketone ketone and polyether ether ketone.

Different examples of the apparatus(es) and method(s) disclosed herein include a variety of components, features, and functionalities. It should be understood that the various examples of the apparatus(es) and method(s), disclosed herein, may include any of the components, features, and functionalities of any of the other examples of the apparatus(es) and method(s) disclosed herein in any combination.

Many modifications of examples, set forth herein, will come to mind of one skilled in the art, having the benefit of the teachings, presented in the foregoing descriptions and the associated drawings.

Therefore, it is to be understood that the subject matter, disclosed herein, is not to be limited to the specific examples illustrated and that modifications and other examples are intended to be included within the scope of the appended claims. Moreover, although the foregoing description and the associated drawings describe examples of the subject matter, disclosed herein, in the context of certain illustrative combinations of elements and/or functions, it should be appreciated that different combinations of elements and/or functions may be provided by alternative implementations without departing from the scope of the appended claims. Accordingly, parenthetical reference numerals in the appended claims are presented for illustrative purposes only and are not intended to limit the scope of the claimed subject matter to the specific examples provided herein.