To improve a method for ultrasonic welding of parts for vehicles and/or aircraft, a method in which an energy director made of non-woven fiber material is arranged between a first fiber composite part and a second fiber composite part to be joined together. A sonotrode is used to join/weld the parts together by pressing on the parts. The energy director is compliant such that a uniform even contact is generated between the first and second fiber composite parts during the welding process.

Provided are a joining structure, a joining method, an exterior body for a wire harness, and a wire harness capable of firmly joining members having different physical properties while reducing the thickness of a joint part. The joining structure 10 joins a first member 1 made of a first resin and a second member 2 made of a second resin, wherein: the second resin has physical properties having a higher foaming ratio than the first resin; and a recessed joint part 3 is provided which reaches at least the inside of the first member 1 from the outer surface side of the second member in a state in which the first member 1 and the second member 2 are superimposed. Furthermore, a method for manufacturing the joining structure 10 comprises the steps of: superimposing a first member 1 made of a first resin and a second member 2 made of a second resin having physical properties having a higher foaming ratio than the first resin; and joining the first member 1 and the second member 2 by forming the recessed joint part 3 by pressing and hot-melting the second member 2 until the recessed joint part 3 reaches at least the inside of the first member 1 from the outer surface side of the second member 2.

Provided are a joining structure, a joining method, an exterior body for a wire harness, and a wire harness capable of firmly joining members having different physical properties while reducing the thickness of a joint part. The joining structure 10 joins a first member 1 made of a first resin and a second member 2 made of a second resin, wherein: the second resin has physical properties having a higher foaming ratio than the first resin; and a recessed joint part 3 is provided which reaches at least the inside of the first member 1 from the outer surface side of the second member in a state in which the first member 1 and the second member 2 are superimposed. Furthermore, a method for manufacturing the joining structure 10 comprises the steps of: superimposing a first member 1 made of a first resin and a second member 2 made of a second resin having physical properties having a higher foaming ratio than the first resin; and joining the first member 1 and the second member 2 by forming the recessed joint part 3 by pressing and hot-melting the second member 2 until the recessed joint part 3 reaches at least the inside of the first member 1 from the outer surface side of the second member 2.

A method of making a storage bag comprising the following steps performed in any order: (a) forming a composite tube having an inner surface comprising a higher melting polymer, an outer surface comprising a lower melting polymer, two ends, and a diameter; (b) flattening the tube in a direction perpendicular to the diameter; (c) forming a joint at one of the ends at a temperature between respective melting points of the higher melting polymer and the lower melting polymer; (d) providing a composite sheet having a first side comprising a higher melting polymer and a second side comprising a lower melting polymer; and (e) disposing the composite sheet over the joint such that the first side comprising a lower melting polymer engages the joint and forming a lap seam over the joint at a temperature between respective melting points of the higher melting polymer and the lower melting polymer, and a storage bag made by such method.

A method of making a storage bag comprising the following steps performed in any order: (a) forming a composite tube having an inner surface comprising a higher melting polymer, an outer surface comprising a lower melting polymer, two ends, and a diameter; (b) flattening the tube in a direction perpendicular to the diameter; (c) forming a joint at one of the ends at a temperature between respective melting points of the higher melting polymer and the lower melting polymer; (d) providing a composite sheet having a first side comprising a higher melting polymer and a second side comprising a lower melting polymer; and (e) disposing the composite sheet over the joint such that the first side comprising a lower melting polymer engages the joint and forming a lap seam over the joint at a temperature between respective melting points of the higher melting polymer and the lower melting polymer, and a storage bag made by such method.

A vehicle lamp includes a lamp housing having an inner space and a welding surface, and a cover that covers the inner space and is joined to the lamp housing by laser welding to be disposed adjacent to another vehicle lamp. The cover includes a design surface portion and a welding leg. An end portion of the outer peripheral portion of the design surface portion on another vehicle lamp side is provided as an adjacent side end portion. The welding leg includes a facing surface portion that protrudes from the adjacent side end portion and faces the other vehicle lamp. The facing surface portion is provided at a position extending from an upper end portion to a lower end portion of the adjacent side end portion.

A vehicle lamp includes a lamp housing having an inner space and a welding surface, and a cover that covers the inner space and is joined to the lamp housing by laser welding to be disposed adjacent to another vehicle lamp. The cover includes a design surface portion and a welding leg. An end portion of the outer peripheral portion of the design surface portion on another vehicle lamp side is provided as an adjacent side end portion. The welding leg includes a facing surface portion that protrudes from the adjacent side end portion and faces the other vehicle lamp. The facing surface portion is provided at a position extending from an upper end portion to a lower end portion of the adjacent side end portion.

A method of forming a component includes additively manufacturing a first subcomponent, the first subcomponent including a first polymer material with a first porosity. The method further includes mating the first subcomponent with a second subcomponent and ultrasonically welding the first subcomponent to the second subcomponent at a weld frequency. The first porosity can be 5% or less.

A method of forming a component includes additively manufacturing a first subcomponent, the first subcomponent including a first polymer material with a first porosity. The method further includes mating the first subcomponent with a second subcomponent and ultrasonically welding the first subcomponent to the second subcomponent at a weld frequency. The first porosity can be 5% or less.

There is provided a method for producing a metal-resin composite which includes a resin member and a metal member having a roughened surface in at least a portion of the surface thereof, the resin member being joined so as to be in contact with at least a portion of the roughened surface. The method includes a step of joining the resin member and the metal member by melting the resin member with the frictional heat generated in the surface of the metal member on its side opposite to the resin member in a state where the metal member and the resin member are superposed. The method includes making adjustment so that when the roughened surface is measured at arbitrary five points by using a confocal microscope according to ISO 25178, the developed area ratio (Sdr) is 5 or more in terms of number-average value.