Continuous fibre-reinforced thermoplastics often are offered as impregnated and consolidated semi-finished products which are known as organic sheets. The thermoplastic matrix leads to several advantages including the thermoformability and weldability. Parts made of organic sheets are frequently produced by forming the semi-finished product into half-shells and stiffening those shells in the course of the process e.g. by the injection moulding of ribs. Larger and more complex parts with hollow body structures can be manufactured e.g. by forming the semi-finished products into half-shells and joining the half-shells. However, the currently available manufacturing technologies for parts made of organic sheets have cap profile shaped joints which prevent the use of the reinforcing fibres across the joint plane. Investigations have proven that overlapping weld joints in organic sheets show much higher strengths than cap profile shaped joints which can be explained by the fibre use across the joint plane. Furthermore, the infrared welding technology was verified as an appropriate process for the welding of organic sheets since no need for additional welding material is given, short heating times can be realized and no contact of the infrared emitters to the joining parts is required. Therefore, the present study shall reveal the high potential of the overlapping welding of organic sheets. Influences on the weld strengths of infrared welded organic sheets are described and potential improvements concerning the materials to be welded as well as the welding process are shown.

Continuous fibre-reinforced thermoplastics often are offered as impregnated and consolidated semi-finished products which are known as organic sheets. The thermoplastic matrix leads to several advantages including the thermoformability and weldability. Parts made of organic sheets are frequently produced by forming the semi-finished product into half-shells and stiffening those shells in the course of the process e.g. by the injection moulding of ribs. Larger and more complex parts with hollow body structures can be manufactured e.g. by forming the semi-finished products into half-shells and joining the half-shells. However, the currently available manufacturing technologies for parts made of organic sheets have cap profile shaped joints which prevent the use of the reinforcing fibres across the joint plane. Investigations have proven that overlapping weld joints in organic sheets show much higher strengths than cap profile shaped joints which can be explained by the fibre use across the joint plane. Furthermore, the infrared welding technology was verified as an appropriate process for the welding of organic sheets since no need for additional welding material is given, short heating times can be realized and no contact of the infrared emitters to the joining parts is required. Therefore, the present study shall reveal the high potential of the overlapping welding of organic sheets. Influences on the weld strengths of infrared welded organic sheets are described and potential improvements concerning the materials to be welded as well as the welding process are shown.