A method of making a vehicle interior component having an integral airbag component is provided. The method includes disposing a polymeric composite sheet having inner and outer surfaces onto a first surface of a mold at a molding station and compressing the sheet between the first surface and a second surface of the mold at the molding station. The method also includes injecting a molten polymer compatible with the polymeric material of the composite sheet into the mold cavity in accordance with a predetermined set of process parameters which are high enough to integrally form at least one airbag component via polymeric interfusion at the inner surface of the composite sheet but are low enough to reduce surface defects on the outer surface of the composite sheet.

A method of making a vehicle interior component having an integral airbag component and a fibrous decorative covering is provided. The method includes providing a polymeric composite sheet and a fibrous decorative covering overlying an outer surface of the composite sheet. The composite sheet is pressed against the covering after the steps of providing to bond the covering to the composite sheet. A molten polymer compatible with the polymeric material of the composite sheet is injected into a mold cavity in accordance with a predetermined set of process parameters which are high enough to integrally form at least one airbag component via polymeric interfusion at the inner surface of the composite sheet but low enough to avoid damaging the covering.

A method of making a trim component having an edge-wrapped, fibrous decorative covering is provided. A fibrous decorative covering overlies and is in contact with an outer surface of a composite sheet. The composite sheet is pressed against an interior portion of the covering to bond the interior portion to the composite sheet while maintaining at least one exterior edge portion of the covering unbonded to the composite sheet. A molten polymer compatible with the polymeric material of the composite sheet is injected in accordance with a predetermined set of process parameters which are high enough to integrally form at least one structural component via polymeric interfusion at the inner surface of the composite sheet but low enough to avoid damaging the covering. The at least one unbonded, exterior edge portion is folded over the composite sheet to form the trim component.

A composite object with more complete and stronger adhesion between the constituent parts includes a substrate and a plastic member formed on a surface of the substrate. The substrate can be made of memory metal. Nano-holes are formed on the surface of the substrate. The composite further includes a combining layer. The combining layer is positioned between the substrate and the plastic member. The nano-holes are at least partially filled with the combining layer, unfilled holes being filled with the plastic constituent in the molten state. The disclosure further provides a method for manufacturing the composite.

A composite panel structure has opposing outer walls or surfaces and a core comprising a plurality of ribs extending between and connected to the outer walls and defining chambers which are filled with expanding foams, non-expanding foams, gases, or a combination thereof. The outer panel surfaces and internal chamber walls or ribs are made of woven or non-woven fibrous material impregnated with one or more resins. The panel structure may be used for making a variety of products including sports equipment such as sports paddles, surfboards, kite boards, skateboards, wakeboards, as well as construction panels for walls, ceilings or floors, display panels, panels for the vehicle industry, furniture, and other structures requiring high strength to weight properties.

A reusable countertop mold in accordance with the present invention includes at least one mold sheet, but generally a plurality of mold sheets are required to extend about a predetermined portion of a periphery of a floor mounted cabinet. The mold sheet is dimensioned and configured to ultimately form a countertop having a predetermined configuration with predetermined dimensions. The mold sheet includes a relatively thin base portion and a wall portion perpendicular to the base portion. The reusable countertop mold further includes a plurality of fastener recesses in an inner side portion of the base portion, the recesses ultimately allowing fasteners to pass through a countertop substrate and into the floor mounted cabinet, after the base portion has been inserted between the countertop substrate and the cabinet. After a countertop forming material has hardened upon the countertop substrate and the mold sheet, the base portion of the mold sheet is slidably removed from between the countertop substrate and the cabinet, thereby allowing the reusable countertop mold to be reused for another countertop forming project.

A universal barrier system includes universal barrier components that may be assembled together to shield floors and walls from moisture and provide a thermal break in an operational area of the universal barrier component. A lap zone of the universal barrier component may allow universal barrier components to be assembled and installed to protect floors, walls, ceilings, footings and the like from moisture and heat gain or loss by minimizing the need for tapes and other joining methods. The universal barrier system may also act as a sound deadening material. The operational area and lap zone of the universal barrier component may be disposed on a vapor block layer to provide some rigidity. The operational area of the universal barrier component may include a thermal break disposed upon the vapor block layer. The thermal break may include an outer protective layer. In addition, universal barrier tape and universal barrier edging may be provided to couple adjoining universal barrier components.

A method for manufacturing a composite molded body in which a metallic molded body and a resin molded body are joined, includes a step of irradiating laser light onto a joining surface of the metallic molded body with the resin molded body in an energy density of 1 MW/cm2 or more and at an irradiation rate of 2000 mm/sec or more to roughen the surface, and a step of placing, in a mold, a portion of the metallic molded body containing the joining surface roughened in the preceding step and injection-molding a resin to obtain a composite molded body. The roughened joining surface of the metallic molded body has a porous structure containing a hole having a maximum depth from a surface exceeding 500 m, and a joining strength between the metallic molded body and the resin molded body is 60 MPa or more.

A simulated brick includes a polymeric core member (20), a mesh layer (30) adhered to the core member, a basecoat layer (43) covering an entirety of the mesh layer, and a finish layer (46) covering an entirety of the basecoat layer. The core member, the mesh layer, the basecoat layer, and the finish layer together define a brick profile portion (11) having first and second lateral sides extending to a planar outer surface to define a first thickness, and an offset portion (12) extending from the first lateral side of the brick profile portion to a lateral end surface and having an outer surface defining a second thickness smaller than the first thickness, the brick profile portion and the offset portion together defining a planar rectangular base surface (16) extending from the second lateral side of the brick profile portion to the lateral end surface of the offset portion.

In a method of producing an automobile fuel tank including a tank body, an outer wall of the tank body being formed of a synthetic resin layer composed of a multilayer configuration, wherein the synthetic resin layer includes an inner body layer and an outer body layer with at least a barrier layer interposed therebetween, and the inner body layer includes a structural member with an air space internally provided, the method includes: forming the outer wall of the inner body layer, the outer body layer, and the barrier layer which is interposed between the inner body layer and the outer body layer, exclusive of the structural member; and welding the structural member only to an inner face of the inner body layer.