Thermoplastic composite component with vibration welded non-parallel surfaces and method for producing the same

A method for joining thermoplastic composite parts, comprising:

• providing a cross member having at least one first flange disposed in a first plane and at least one second flange disposed in a second plane that is non-parallel to the first plane, the cross member comprising a first thermoplastic composite material;
• providing a rail having at least one first joining surface disposed in the first plane and at least one second joining surface disposed in the second plane, the rail comprising a second thermoplastic composite material;
• disposing the cross member to the rail so that the at least one first flange and the at least one first joining surface are in contact with one another, and the at least one second flange and the at least one second joining surface are in contact with one another;
• forcing the at least one second flange and the at least one second joining surface against one another;
• and
• welding the at least one first flange and the at least one first joining surface together using a vibration welding process that includes subjecting one of the cross member or the rail to oscillatory motion;
• wherein the oscillatory motion and the forcing of the at least one second flange and the at least one second joining surface against one another causes the at least one second flange and the at least one second joining surface to be welded.