A mold for producing a metal-resin composite by press-forming a metal member and integrally molding the metal member that is press-formed and a resin material includes an upper mold and a lower mold that sandwich the metal member and the resin material. The upper mold includes a first press surface for press-forming the metal member and a second press surface for integrally molding the metal member and the resin material. A distance between the first press surface and the lower mold is shorter than a distance between the second press surface and the lower mold.

A liquid crystal polymer composite film is formed from a resin composite including one or more liquid crystal polymers and one or more fillers. The liquid crystal polymer composite film has a thickness in the range of 10 μm-200 μm and a ratio of the in-plane dielectric permittivity in the machine direction to the transverse direction in the range of 1.0-1.4 over a frequency range of 1 Ghz to 10 Ghz. A metal-clad laminate includes the liquid crystal polymer composite film and a metal clad layer laminated to a major surface of the liquid crystal polymer composite film. The metal-clad laminate may be included as part of an antenna.

A method of preparing a structure is provided. The method includes providing an initial structure; casting a first material in one or more void volumes of the initial structure; removing the initial structure from the first material; obtaining a cast structure comprising the first material; coating a second material on the cast structure; casting a third material using the coated cast structure; removing the first material; and obtaining a final structure. In various embodiments, the initial structure can include a first initial structure and a second initial structure and casting a first material in one or more first void volumes of the first initial structure and in one or more second void volumes of the second initial structure. In various embodiments, the method includes assembling the first cast structure and the second cast structure and obtaining an assembled structure comprising the first cast structure and the second cast structure.

A casing structure including a plastic casing, at least one metal component, and a conductive layer is provided. The at least one metal component is disposed on the plastic casing, and at least one side surface of the at least one metal component is covered by the plastic casing. The conductive layer is disposed on the metal component and extends to the plastic casing. In addition, a manufacturing method of the casing structure is also provided.

A method for producing metal-polymer composites which include at least one metal part and at least one part made of a polymer composition, the method including the steps of: treating the surface of at least one metal part at least partially with a solution of triazine thiol derivative to obtain a treated metal surface; and contacting the treated metal surface at least partially with at least one polymer composition so as to obtain a metal-polymer composite, wherein the polymer composition includes at least one semi-crystalline polyamide. Also, a metal-polymer composite that includes at least one part made of a polymer composition and at least one metal part and that is obtainable by the method and to a product including the metal-polymer composite.

A method for chemically polishing a metal surface within a metal-polymer composite, where the composite includes at least one metal part and at least one part made of a polymer composition, the method including the step of: (i) contacting the surface of at least one metal part at least partially with an aqueous solution including an oxidizing agent and an alkaline agent, at a temperature and for a duration sufficient to obtain a shiny metal surface. Also a metal-polymer composite that includes at least one part made of a polymer composition and at least one chemically polished metal part and that is obtainable by the method and to a product including the metal-polymer composite.

The present invention relates to a polybutylene terephthalate composition, comprising as component (A) polybutylene terephthalate (PBT) resin, as component (B) polyester copolymer with melting point from 105° C. to 185° C., as component (C) vinyl-based polymer, and optionally as component (D) glass bubbles. The present invention also relates to a composite of plastic/metal hybrid, which comprises metal article and the polybutylene terephthalate composition of the present invention which is joined to and integrated with the metal article.

An injection molding unit includes a main unit and an optional unit, the main unit accommodating a first injection molding machine that molds an integrated product by injecting a first molding material into a cavity which is defined by a lower die and an upper die and in which an insert member is disposed. The optional unit includes at least one of a member molding unit that accommodates a second injection molding machine that molds the insert member by injecting a second molding material or a press molding machine that molds the insert member in press molding, and a robot unit that accommodates a robot that performs placement operation of placing the insert member in the cavity or transport operation of transporting the integrated product molded by the first injection molding machine. The main unit is so configured that the optional unit is attachable thereto and detachable therefrom.

A thrust reverser cascade for an aircraft nacelle includes a plurality of blades having a first and a second surface, the blades being connected to members connected to attachment flanges for attaching the thrust reverser cascade to the nacelle. At least one of the surfaces of the blades is covered with at least one layer of fibers, each layer including a plurality of fiber pieces which are pre-impregnated with resin. The fiber pieces are superimposed on one another, positioned parallel to the aerodynamic surface of the blade and oriented in different directions.

A light-weight gear including: an annular tooth portion made of metal; a shaft extending along a central axis of the tooth portion and made of metal; and a coupling element configured to couple the shaft to the tooth portion and made of a resin, in which a joining part between the shaft and the coupling element and a joining part between the tooth portion and the coupling element are provided with irregularities configured to be engaged with one another in a circumferential direction, and corners of the irregularities are rounded to release a stress. Also, provided is a manufacturing method of a light-weight gear including: disposing the tooth portion and the shaft in a mold and injecting a molten resin into a cavity of the mold, thereby simultaneously performing injection molding of the coupling element and joining the coupling element to the tooth portion and the shaft.