A structural reinforcement for an article including a carrier (10) that includes: (i) a mass of polymeric material (12) having an outer surface; and (ii) at least one fibrous composite Insert (14) or overlay (980) having an outer surface and including at least one elongated fiber arrangement (e.g., having a plurality of ordered fibers). The fibrous Insert (14) or overlay (980) is envisioned to adjoin the mass of the polymeric material in a predetermined location for carrying a predetermined load that Is subjected upon the predetermined location (thereby effectively providing localized reinforcement to that predetermined location). The fibrous insert (14) or overlay (980) and the mass of polymeric material (12) are of compatible materials, structures or both, for allowing the fibrous insert or overlay to be at least partially joined to the mass of the polymeric material. Disposed upon at least a portion of the carrier (10) may be a mass of activatable material (126). The fibrous insert (14) or overlay (980) may include a polymeric matrix that includes a thermoplastic epoxy.

A resin part for a vehicle includes a fender main body formed of a fiber-reinforced resin using a resin fiber, and a resin structure section formed of the same resin material as the resin fiber, provided at least on an outer surface of the resin part main body exposed on an outer side of a vehicle, and formed integrally with the resin part main body.

Composite fasteners, associated blanks and also methods and apparatus for the installation of such fasteners are disclosed. An exemplary composite rivet disclosed comprises an elongated body including braided reinforcement fibers embedded inside the body and supported in a matrix material. Also disclosed are structural assemblies comprising composite fasteners and panels or other parts comprising composite and/or other materials.

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 of mechanically securing a first object including a thermoplastic material in a solid state to a second object with a generally flat sheet portion, with a perforation of the sheet portion, and with the sheet portion having an edge along the perforation is provided, wherein the first object is positioned relative to the second object so that the edge is in contact with the thermoplastic material and wherein mechanical vibration energy is coupled into the assembly including the first and second objects until a flow portion of the thermoplastic material due to friction heat generated between the edge and the thermoplastic material becomes flowable and flows around the edge to at least partially embed the edge in the thermoplastic material. After the mechanical vibration stops, the thermoplastic material is caused to re-solidify, whereby the re-solidified thermoplastic material at least partially embedding the edge anchors the first object in the second object.

A joint between at least one element of metal material and at least one element of plastic material is obtained by pressing these elements in contact against each other, with a simultaneous application of heat. A cladding of metal material and/or of plastic material is applied above the joint by additive manufacturing technology.

An insulating element for insulating a structural element in a vehicle including a carrier element having an edge region and an expandable material which is provided at least on the edge region on the carrier element. The expandable material projects beyond the edge region of the carrier element in at least one direction so that the expandable material forms a flexible projection in this at least one direction.

A method produces plastic/metal hybrid components, in particular for the automotive field. A plastic compound is injected into a tool mold, and the tool mold has a core onto which a metal is injected. The plastic compound is then injected into the tool mold such that the metal is back-molded with the plastic compound and is fixed to the plastic in order to produce a blank. The tool mold is used to produce at least one depression in the surface of the blank, the depression being at least partly filled with a metal as part of a first additional processing.

Methods of producing core layers with a variable basis weight across a width of the core layer and with a substantially uniform thickness across the width of the core layer are described. The core layers can be used in wall panels such as those present in recreational vehicle panels. Systems and various materials used to produce the core layers and articles are also described.

A method of forming multilayer polymer composite particles includes coextruding a multilayer polymer composite sheet having alternating first and second polymer layers. The multilayer polymer composite sheet is divided into a plurality of anisotropic multilayer polymer composite microparticles.