A synthetic metal system comprising a frame member comprising a cellular structure including a plurality of openings; and a matrix material comprising a polymeric material, wherein the matrix material is configured to at least partially penetrate one or more of the plurality of openings in the frame member such that the frame member is at least partially encased within the matrix material.

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.

The invention relates to a device comprising: a first layer (11) of a thermoformable material that is inelastically deformable in a thermoforming temperature range, a second layer (1) of a viscoelastic material that is elastically deformable in a temperature range including a use temperature range of the device and the thermoforming temperature range, and wherein: the use temperature range is lower than the thermoforming temperature range, the first layer is bonded to the second layer, the thermoformable material is elastically deformable and more rigid than the viscoelastic material in the use temperature range, the thermoformable material is less rigid than the viscoelastic material in the thermoforming temperature range.

Metal rib overmolding joining including creating geometrical features in reinforcements for interconnecting a three-dimensional metal reinforcement to a metal base plate of an overmolding part in order to transfer load forces. Interlocked reinforcement is pre-assembled or assembled in an injection molding tool. Geometric features are positioned and joined creating a connection geometry that is overmolded. The joints created between the metal reinforcements are done without a welding process.

A three-dimensional overmolding and process for manufacturing same. The three-dimensional overmolding has a three-dimensional structure with overmolding, which gives significant performance benefits. Assembly and joining of reinforcements is done before the overmolding or in the injection molding tool. The three-dimensional overmolding meets predetermined structural requirements without requiring secondary operations and at a lower mass and cost. The structural benefits are due to the three dimensional shape in combination with the benefit of the overmolding process.

Described is a method for manufacturing a diaphragm assembly through the use of injection molding. The method can avoid the use of PTFE as a chemically resistant coating. Further, the method can increase overall adherence of a polymer diaphragm to an insert through the use of an interference surface on at least the surface of a head of the insert.

Lighting systems are described. A lighting system includes a first lead frame portion and a second lead frame portion. The first lead frame portion has at least a top surface, a bottom surface, and an opening. The second lead frame portion is within the opening of the first lead frame portion and has at least a top surface and a bottom surface. Light-emitting diode (LED) devices are each mechanically and electrically coupled to the top surface of the first lead frame portion and the top surface of the second lead frame portion. An electrically insulating and optically reflective material is disposed over exposed regions of the top surfaces of the first and second lead frame portions.

A method for manufacturing three-dimensional items with flexible walls is provided, by method of a mold and counter-mold between which a volume corresponding to that of the item to be obtained is delimited. The item is made up of laminar parts which are mounted on a template that is fixed to the inner surface of the mold. The laminar parts are joined to one another by means of a material which is injected in molten state through a network of conduits delimited between the counter-mold, template and the facing edges of adjacent laminar parts. The template is made of an elastically deformable material and has a three-dimensional configuration.

A method for producing a plastic-coated loudspeaker housing comprises the putting together of a loudspeaker housing from a plurality of housing wall elements. The put-together loudspeaker housing is placed in a mold. This is followed by a surface coating of the put-together loudspeaker housing by introducing a liquid, curable plastic into the mold.

The present invention relates to a method for producing a shaped article, a shaped article obtained therefrom and the use of the shaped article in vehicle door intrusion beams, structural inserts in body in white, bumper beams, instrument panel cross members, seating structural inserts and front-end module structures.