The invention relates to a structural member comprising: a core portion that defines at least one anchor point, the core having at least one surface, a fibre tow arranged in a closed loop on the surface of the core portion, the loop defining a boundary of a space which contains the at least one anchor point, and a protective shell formed from a woven fibre sheet material which covers the fibre tow, and in which the core, fibre tow and the protective shell are impregnated and bound together by a cured resin. The invention also relates to a method of constructing a structural member.

A component including at least one joint, at which a joining connection to a further component is to be formed later, is provided. A joining element having a holding section is pressed into the component, and the joining element also has a functional section, by way of which at least one further function can be implemented. The holding section of the joining element is arranged in a passage hole, and the passage hole is widened in at least one edge region by an embossing. The holding section of the joining element is pressed into the passage hole and is connected to the hole wall in a force-fitting and/or form-fitting manner and engages in the embossing. A component combination of at least two components which includes such a component and a method for producing the component and the component combination are also provided.

A component including at least one joint, at which a joining connection to a further component is to be formed later, is provided. A joining element having a holding section is pressed into the component, and the joining element also has a functional section, by way of which at least one further function can be implemented. The holding section of the joining element is arranged in a passage hole, and the passage hole is widened in at least one edge region by an embossing. The holding section of the joining element is pressed into the passage hole and is connected to the hole wall in a force-fitting and/or form-fitting manner and engages in the embossing. A component combination of at least two components which includes such a component and a method for producing the component and the component combination are also provided.

A piston for a heavy duty diesel engine including a composite layer forming at least a portion of a combustion surface is provided. The composite layer has a thickness greater than 500 microns and includes a mixture of components typically used to form brake pads, such as a thermoset resin, an insulating component, strengthening fibers, and an impact toughening additive. According to one example, the thermoset resin is a phenolic resin, the insulating component is a ceramic, the strengthening fibers are graphite, and the impact toughening additive is an aramid pulp of fibrillated chopped synthetic fibers. The composite layer also has a thermal conductivity of 0.8 to 5 W/m.Math.K. The body portion of the piston can include an undercut scroll thread to improve mechanical locking of the composite layer. The piston can also include a ceramic insert between the body portion and the composite layer.

The present invention provides a method for producing a joined body, the method including: disposing a joining member between a member A containing a thermoplastic resin and a member B containing a thermoplastic resin, the joining member including a sheet part containing a thermoplastic resin, and a plurality of protrusion parts integrally formed with the sheet part on at least one surface of the sheet part, the protrusion parts containing a thermoplastic resin; and melting at least a part of the joining member to join the member A and the member B to obtain a joined body thereof.

The present invention provides a method for producing a joined body, the method including: disposing a joining member between a member A containing a thermoplastic resin and a member B containing a thermoplastic resin, the joining member including a sheet part containing a thermoplastic resin, and a plurality of protrusion parts integrally formed with the sheet part on at least one surface of the sheet part, the protrusion parts containing a thermoplastic resin; and melting at least a part of the joining member to join the member A and the member B to obtain a joined body thereof.

A process is provided for producing a stable fabric comprising: 1) providing a first fabric formed from reinforcing fibers, 2) providing a nonwoven web produced from fibers, having softening temperature lower than said reinforcing fibers, on at least 1 one side of said first fabric to form a structure, 3) heating said structure to a temperature between the softening temperature and melting temperature of said nonwoven web, and 4) cooling said structure to thereby provide a stable two-dimensional fabric. In a preferred embodiment, the structure of step 2) is put into a mold prior to heating step 3), heating said structure in the mold according to step 3), cooling said structure in the mold according to step 4) and thereby providing a three-dimensional shaped article. A product is also provided produced by these processes.

Embodiments of the present disclosure may provide a method of forming a molded composite member comprising the following steps, not necessarily in the order recited: selecting a mold insert having an exterior shape conforming to a shape desired to be formed in a first composite member that is pre-impregnated with thermosetting resin; screwing the mold insert into a mold; conforming a surface of the first composite member to the mold insert and mold; curing the resin in the first composite member to render the first composite member rigid and to form a shape in the first composite member corresponding to the shape of the mold insert and the mold; forming a first hole in the first composite member adjacent the shape; forming a second hole in a second member; positioning a washer in the shape in the first composite member, the washer having an exterior conforming with the shape; and extending a linear fastening member through a washer hole, the first hole in the first composite member, and the second hole in the second member.

Embodiments of the present disclosure may provide a method of forming a molded composite member comprising the following steps, not necessarily in the order recited: selecting a mold insert having an exterior shape conforming to a shape desired to be formed in a first composite member that is pre-impregnated with thermosetting resin; screwing the mold insert into a mold; conforming a surface of the first composite member to the mold insert and mold; curing the resin in the first composite member to render the first composite member rigid and to form a shape in the first composite member corresponding to the shape of the mold insert and the mold; forming a first hole in the first composite member adjacent the shape; forming a second hole in a second member; positioning a washer in the shape in the first composite member, the washer having an exterior conforming with the shape; and extending a linear fastening member through a washer hole, the first hole in the first composite member, and the second hole in the second member.

A structural component for an aircraft or spacecraft, comprising: a planar member; a reinforcing member which projects from the planar member and is rigidly connected thereto; the reinforcing member comprising at least a foam layer and a cover layer, a plurality of pins extending at least through the foam layer and the cover layer, and at least the pins and the cover layer comprising a curable matrix.