A disclosed insert molding method includes installing a first insert piece between a first mold and a second mold such that a smallest distance in a gap between the first insert piece and the first mold is smaller than a smallest distance in a gap between the first insert piece and the second mold, the first insert piece including a first through-hole of which width is larger than the smallest distance in the gap between the first insert piece and the first mold; and supplying a resin to a mold gap between the first insert piece and the first mold or the second mold, thereby to fill the mold gap with the resin, while the first insert piece and the first mold are kept to abut each other.

A composite structural body (A) includes a first metal member (M1) having a plate-like shape, a second metal member (M2) having a plate-like shape, and a resin member (R) that integrates the first metal member (M1) and the second metal member (M2) with each other. The resin member (R) includes a first resin layer (R1) that coats astride one main surface of the first metal member (M1) and one main surface of the second metal member (M2), and a second resin layer (R2) that coats astride another main surface of the first metal member (M1) and another main surface of the second metal member (M2). The composite structural body (A) is provided as a composite structural body that has satisfactory moldability, that is capable of securing sufficient strength, and that is suitable as a component of a structure such as a vehicle body.

A resin formed article, comprising a main body that includes a first resin; a functional layer that is disposed at at least a portion of a surface of the main body and includes a fiber and a second resin; and a projection that is disposed on the functional layer and includes the first resin and the second resin.

An in-mold electronic structure according to the present invention comprises a film with a design; a first plastic resin disposed under the film, and a second plastic resin disposed under the first plastic resin, wherein an electronic circuit is formed on a top side or both sides of the second plastic resin, wherein an electronic device is mounted on the top side or the both sides of the second plastic resin, wherein the film, the first plastic resin, and the second resin with the electronic circuit and the electronic device, are integrated.

A vehicle-window glass assembly includes a vehicle-window glass and its injection-molded encapsulation; and an over-molded bolt including a base, a thread rod and an injection-molded part. One end of the thread rod is fixedly connected to the base, and the injection-molded part covers at least a part of the base. The injection-molded encapsulation covers at least a part of the injection-molded part such that the over-molded bolt and the vehicle-window glass are fixed to each other, and a material of the injection-molded part has a tensile strength greater than that of a material of the injection-molded encapsulation. This vehicle-window glass assembly can b e adapted to various vehicle models with a large gap between a surface of a vehicle-window glass and a vehicle-door sheet metal on which the vehicle-window glass requires to be mounted.

A method of manufacturing a motor case for an electric motor of an e-boosting device in which the motor case is received within an outer housing to cooperatively define a coolant jacket. The method includes forming a shell member. The method also includes overmolding a dam member to the shell member. The dam member projects from an outer surface of the shell member. The overmolding of the dam member includes forming a molded through-hole through the dam member. The dam member and the outer surface are configured to define a fluid boundary for a coolant of the coolant jacket when the motor case is received in the outer housing. The through-hole defines a passage for the coolant in the coolant jacket.

The invention relates to a stable one piece wheel, which is particularly suitable for cycles having an increased system weight such as electrically powered bicycles or cargo bikes, and a method producing said vehicle wheel. Said vehicle wheel comprises an annular portion (110), a plurality of spokes (120) and a hub portion (130) integrally formed by mould injection of fibre reinforced or carbo nano tubes containing thermoplastic, wherein each of the plurality of spokes (120) comprise a substantially Z-shaped cross section with a middle leg (122) and a pair of outer legs (121, 123), wherein the angle (γ) enclosed by each of the pair of outer legs and the middle leg is greater than a right angle and wherein the length of the middle leg (122) increases from the annular portion (110) toward the hub portion (130).

A method of manufacturing a chute panel of an airbag assembly. The method comprises forming a substrate from a first material to have a body having first and second ends and a longitudinal axis extending therebetween and a void residing in the body. The method further comprises forming a chute and a chute door from a second material. The chute comprises a base molded onto the substrate body and one or more sidewalls extending from the base. And wherein forming the chute door comprises filling the void in the substrate body with the second material to form the chute door.

The invention relates to a hybrid structure comprising a first component having a base and an upstanding wall extending from the base, the first component having an interior enclosed between the upstanding wall and the base, and a thermoplastic second component moulded to the first component, the second component comprising a reinforcing portion for structurally reinforcing the first component, the reinforcing portion extending in a longitudinal direction of the first component and located in the interior of the first component, the thermoplastic second component further comprising a locking portion that extends adjacently over at least part of an exterior of the first component, wherein the reinforcing portion and the locking portion are integrally formed, thus interlocking the first component in the thermoplastic second component. The invention relates as well to a method for manufacturing such a hybrid structure, and to a vehicle comprising such a hybrid structure.

A method of over-molding a thermoplastic material over fabric includes: precision forming a mold cavity to match the final dimensions of a finished product; cutting a piece of fabric to a correct size; fixedly securing the fabric piece in the mold cavity; and injecting a thermoplastic material into the mold cavity at an appropriate temperature and pressure, on top of the fabric piece. The method may further include heating the thermoplastic material to a temperature for melting a surface layer of the fabric when injected thereon, and cooling of the thermoplastic material and fabric for bonding of the thermoplastic material to the surface of the fabric. The method may further include adding one or more additives from the group of additives consisting of: a UV stabilizer, an anti-blocking agent, a slip agents, a plasticizer, and a flame retardant; and securing a cord member onto an exposed portion of the fabric.