A joining method for joining a first member having a hole that is opened on at least one surface, to a second member including a material of which a melting temperature is lower than that of a constituent material of the first member, includes: laminating the second member on the first member so as to cover an opening of the hole; and introducing that material of the second member which is softened or melted into the hole through the opening and curing the material of the second member.

A joining method for joining a first member having a hole that is opened on at least one surface, to a second member including a material of which a melting temperature is lower than that of a constituent material of the first member, includes: laminating the second member on the first member so as to cover an opening of the hole; and introducing that material of the second member which is softened or melted into the hole through the opening and curing the material of the second member.

A joint member (100) includes a metal component (12) and a composite component (14) which are joined by a joint (10) formed at a non-planar joint interface (18) defined by a textured surface portion (28) of the metal component (12) and a solidified melted area (24) of the composite component (14). The solidified melted area (24) adjacent to the joint interface (18) is characterized by a plurality of non-contiguous solidification boundaries (22) and a non-contiguous dispersion of porosity (16). A method includes forming a textured surface portion (28) on the metal component (12), pressing the textured surface portion (28) into the surface of the composite component (14) to form depressions (32) in the composite component (14), such that a joint interface (18) is defined by the surfaces of the textured surface portion (28) and the composite depressions (32), heating the joint interface (18) to melt an area of the composite component (14) adjacent to the joint interface (18), and solidifying the melted area (24) to the form a joint (10) at the joint interface (18).

A joint member (100) includes a metal component (12) and a composite component (14) which are joined by a joint (10) formed at a non-planar joint interface (18) defined by a textured surface portion (28) of the metal component (12) and a solidified melted area (24) of the composite component (14). The solidified melted area (24) adjacent to the joint interface (18) is characterized by a plurality of non-contiguous solidification boundaries (22) and a non-contiguous dispersion of porosity (16). A method includes forming a textured surface portion (28) on the metal component (12), pressing the textured surface portion (28) into the surface of the composite component (14) to form depressions (32) in the composite component (14), such that a joint interface (18) is defined by the surfaces of the textured surface portion (28) and the composite depressions (32), heating the joint interface (18) to melt an area of the composite component (14) adjacent to the joint interface (18), and solidifying the melted area (24) to the form a joint (10) at the joint interface (18).

A joining method for joining together a first member in which fiber material is mixed into a first resin, and a second member that includes at least a second resin, includes abutting the first member and the second member together, and softening or melting the first resin of the first member and the second resin of the second member that are adjacent to abutting surfaces of the first member and the second member; and stirring a joint forming portion formed by the softened or melted first resin of the first member and the softened or melted second resin of the second member, and the fiber material included in the softened or melted first resin of the first member, in a direction inclined with respect to the abutting surfaces, and hardening the joint forming portion.

A joining method for joining together a first member in which fiber material is mixed into a first resin, and a second member that includes at least a second resin, includes abutting the first member and the second member together, and softening or melting the first resin of the first member and the second resin of the second member that are adjacent to abutting surfaces of the first member and the second member; and stirring a joint forming portion formed by the softened or melted first resin of the first member and the softened or melted second resin of the second member, and the fiber material included in the softened or melted first resin of the first member, in a direction inclined with respect to the abutting surfaces, and hardening the joint forming portion.

A polymer composite and its method of manufacture using a recycled multilayer material. An example of the recycled multilayer material is comprised of a polyethylene/polyethylene terephthalate/aluminum film that may be extruded with organic filler to obtain desirable performance in wood-substitute products such as deck boards, railing, fencing, pergolas, residential cladding/siding, sheet products, and other applications.

A polymer composite and its method of manufacture using a recycled multilayer material. An example of the recycled multilayer material is comprised of a polyethylene/polyethylene terephthalate/aluminum film that may be extruded with organic filler to obtain desirable performance in wood-substitute products such as deck boards, railing, fencing, pergolas, residential cladding/siding, sheet products, and other applications.

An apparatus for roll forming thermoplastic composites comprises a plurality of thermoplastic composite material spools, a plurality of thermoplastic composite material rollers, a plurality of sheet metal spools, a plurality of welding rollers, an oven, a forming roller, a pair of pinch rollers. The thermoplastic composite material spools retain plies of thermoplastic composite material. The plies flow through the thermoplastic composite material rollers to form a layup. The sheet metal spools retain metal sheets. The metal sheets and the layup flow through the welding rollers to form a metal composite material laminate. The oven heats the metal composite material laminate. The forming roller imparts a curvature to the metal composite material laminate. The pinch rollers receive the metal composite material laminate from the forming roller, pull the metal composite material laminate, and output the metal composite material laminate in a heated and compressed state.

The present invention is directed to a foam-injected slat and a method of manufacturing thereof used in building fencing, privacy screens, pergolas, louvers, wall claddings, and other similar types of structures. Use of foam-injected slats in the aforementioned structures provides noise reduction, heat insulation, and vibration absorption. In addition, they are lightweight, strong, durable in heavy weather conditions, environmentally friendly, easy to install, and cost effective. Lastly, the manufacturing process enables the forming of a special locking mechanism that further strengthens the foam-injected slats.