A composite structure comprises stacked sets of laminated fiber reinforced resin plies and metal sheets. Edges of the resin plies and metal sheets are interleaved to form a composite-to-metal joint connecting the resin plies with the metal sheets.

A force-attenuating system that is interposed between an exterior surface and an interior surface, either or both of which may be subjected to percussive forces. The system has a ceiling that is positioned proximate the exterior surface and one or more inverted hat-shaped force-attenuating units with sidewalls extending inwardly convergingly away from the ceiling. Some of the units have a floor that is positioned proximate the interior surface. Optionally the force-attenuating units may be configured as clover-leaf structures with a central region and hemi-pear-shaped lobes extending therefrom. Within the lobes is a floor that is positioned proximate the interior surface. The force-attenuating system may be deployed in an automotive or non-automotive environment.

A roof element and a process for the production of a roof element are provided, which may have the steps of providing a polymer mixture; admixing an organosiloxane compound with the polymer mixture; a mixing of the polymer mixture, with the organosiloxane compound admixed, with an isocyanate compound to give a polyurethane material and introduction of the polyurethane material into a mold cavity of a foaming mold in a manner such that the polyurethane material reacts to completion and a molded section of the roof element is shaped in the mold cavity wherein the organosiloxane compound is accumulated at the surface of the molded section, wherein in a surface layer of thickness from 0.5 m to 20 m of the molded section, the organosiloxane compound is accumulated; and demolding of the roof element from the foaming mold.

The invention concerns a method for the production of a composite component from at least one hollow profile base element and at least one supporting element positioned in the interior of the at least one hollow profile base element.

A structural automotive sub frame component (10) that is formed from a sheet molding compound having carbon fibers. The three dimensional structure is formed of a resin fiber mixture having a resin material infused with carbon fibers having a length of about 12.5 mm (0.5 inches) dispersed throughout the structural automotive sub frame component (10) and an even manner such that there are no resin rich areas or knit lines present. The absence of knit lines provides a structural automotive sub frame component (10) that has a high degree of flex modulus, tensile strength properties well also providing a greater breaking load property due to the absence of knit lines.

A vehicle roof stiffener includes at least one fiber reinforced polymer (FRP) portion and at least one metal or metal alloy portion. The FRP portion includes at least one transition structure including a metal or a metal alloy. At least some of the fibers of the FRP portion are embedded in the transition structure. The metal or metal alloy portion is secured to the transition structure of the FRP portion. In an example vehicle roof stiffener, the metal portion extends parallel to a longitudinal axis of a vehicle, and the FRP portion extends transverse to the longitudinal axis. The example vehicle roof stiffener may include a front FRP portion, a rear FRP portion, and two metal side portions. The metal side portions and the FRP portions may be joined by welding the transition structures to the metal portions.

A method for producing an arrangement for a vehicle roof can have the steps of providing a first element with a first end and a second end, the element being couplable by the first end to the vehicle roof. The method can also have the steps of providing a pumpable substance with predetermined material properties, and applying the provided substance by injection molding at a predetermined position at the second end of the first element and thereby forming a second element such that the second element is coupled to the first element and is pivotable relative to the first element about an axis of rotation (A). An arrangement and system for a vehicle roof is also provided.

Sinusoidal shaped member units and support member units are parts that form pre-stressed assemblies having flexural properties. Sinusoidal shaped members are relaxed material members that have been elastically deformed. Support members maintain the elastically deformed state of the sinusoidal shaped members. The sinusoidal shaped members and support members are organized into pre-stressed curvilinear assemblies containing stored elastic potential energy that is equal to the work done by the forces that deformed their pre-stressed structure. The assemblies' sinusoidal shaped members and support members are adapted to use materials having exceptional mechanical properties and flexural strength. This includes nano-composites. The assemblies' pre-stressed state enhances its mechanical, electrical and structural performance. The size, number, density and possible geometric configurations of the sinusoidal shaped member units and support member units within an assembly/structure is vast. Products of this sinusoidal building system have mechanical and structural applications and can be manufactured using an automated process.

The present disclosure relates to a method of manufacturing a vehicular hybrid suspension arm and a hybrid suspension arm manufactured using the same. The method of manufacturing a hybrid suspension arm includes preparing an assembly of a ball stud and a bearing; preparing a suspension arm body; attaching a ball joint pipe and bush pipes to the suspension arm body; manufacturing a suspension arm main body by inserting the assembly of the ball stud and the bearing into the ball joint pipe; inserting the suspension arm main body into a mold in which a plurality of fixing pins are formed; injecting an insert molding into a ball joint portion comprising the ball joint pipe and the ball stud in a direction of an upper surface of the ball joint pipe through the mold; and inserting and assembling bushes into the bush pipes.

A device and a method are provided for setting a press-in element into a workpiece at a predetermined location. The device includes main body; a fixing unit, which is attached to the main body and which is designed to fix the workpiece; and a processing unit, which is attached to the main body and includes: a boring unit, which is designed to create a bore in the workpiece fixed by the fixing unit; and a pressing unit, which is designed to press a press-in element into the bore. The method fixes the workpiece; creates a bore in the workpiece; positions a press-in element over the bore; and presses the press-in element into the bore, wherein a single device is used to carry out the method.