A composite sandwich panel assembly including an open area core, a high gloss surface sheet, and a structural skin. The open are core defines a plurality of pores and has a first face and an opposing second face. The high gloss surface sheet is adhered to the first face of the open area core by a first adhesive layer. The high gloss surface sheet has a high gloss surface. The structural skin is adhered to the second face of the open area core by a second adhesive layer. A process for forming the composite sandwich panel assembly includes positioning the high gloss surface sheet, joining the first face of the open area core to the high gloss surface sheet with a first adhesive layer intermediate therebetween, and joining the structural skin to the second face of the open area core with a second adhesive layer intermediate therebetween.

A joined structure, including: two members made of materials having different coefficients of linear expansion; and an adhesive layer arranged between the two members to join the two members together, wherein the adhesive layer includes at least an end portion in one direction parallel to a plane direction of the adhesive layer and a center portion in the one direction, and a thickness in the end portion is greater than a thickness in the center portion.

Methods of producing polymer-metal hybrid components that are bonded by C—O-M bonds at the interface using at least one of the hot pressing, rolling, and injection molding methods to create chemical bond formation conditions at the polymer and metal interface. When the thermal cycle and compressive pressure specified herein is combinationally created at the polymer and metal interfaced, strong C—O-M bonds forms at the interface and strongly bonds the metal and polymer together through the reaction carbonyl groups (C═O) in polymer and the metal surface. For polymers lacking enough carbonyl groups, new functional groups can be in-situ generation through introducing distributed air pockets at the polymer-metal interface for forming 3-dimensional distributed C—O-M bonds at the interface.

A component part for a motor vehicle having a hollow profile portion of a fiber-reinforced plastic and a load introduction element of a metal material. The hollow profile portion and the load introduction element are connected in a common connection portion via a nondetachable, glued plug-in connection in which an end portion of the load introduction element and an end portion of the hollow profile portion engage in one another by positive engagement. The end portion of the load introduction element has a spline with teeth extending in longitudinal direction of the common connection portion so that the stiffness of the end portion of the load introduction element reduced in longitudinal direction of the common connection portion.

Disclosed are apparatus and method for manufacturing a metal-composite hybrid part. The apparatus for manufacturing a metal-composite hybrid part includes: a feeder roller feeding a composite tape to a metal base material; a heat supply device applying heat to the metal base material and the composite tape; a first pressure roller pressing and bonding the metal base material and the composite tape, bonded to each other by heat applied through the heat supply device, to each other; a cooling roller cooling the metal base material and the composite tape bonded to each other by the first pressure roller; and a second pressure roller applying heat and pressure to the metal base material and the composite tape, cooled by the cooling roller.

An apparatus is configured to manufacture a metal-resin composite by press-molding a metal plate and a resin material. The apparatus includes an upper mold and a lower mold for sandwiching the metal plate and the resin material, and an elastic member attached to a molding surface of the lower mold. A cavity for disposing the resin material is provided by the upper mold and the lower mold. The elastic member is disposed to seal the resin material into the cavity by pressing the metal plate against the upper mold.

A system for insulating a structural element in a motor vehicle including a structural element having a first constituent part and a second constituent part which are joined together at a first joining point and a second joining point and form a cavity. The system furthermore includes a device having a carrier and a first expandable adhesive, wherein the carrier is arranged on the first constituent part of the structural element by way of a fastening element. The system furthermore includes a second expandable adhesive which is arranged on the second constituent part of the structural element. In this case, the first expandable adhesive and the second expandable adhesive are configured, and arranged, in such a way that, after the adhesives have been expanded, the device and the second expandable adhesive substantially completely fill a cross section of the structural element.

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.

A lightweight suspension assembly for a vehicle includes a suspension upright or knuckle provided with a bearing connection interface for receiving at least part of a wheel bearing, and with a first molded portion made of a first polymeric material; the assembly further includes at least one arm having a second molded portion made of a second polymeric material, and at least one joint member coupling the arm to the suspension upright/knuckle in such a manner to allow a relative rotation between the arm and the suspension upright/knuckle about at least one rotation axis (B); the first and second molded portions are arranged onto a first surface and, respectively, a second surface of the joint member, in such a manner that the first and second molded portions are coupled in a non-releasable manner to the joint member.

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.