In the present invention, it is possible to reduce the occurrence of a local deformation in a plate material during solidification and shrinkage of an injection molding material. The composite material injection molding method includes an injection step of injecting an injection molding material containing reinforcing fibers onto one surface of a plate material; and a molding step of solidifying the injection molding material to mold a frame part so as to surround the outer periphery of the plate material and to mold a rib so as to define an inner peripheral-side space on the inner peripheral side of the frame part. In the injection step, the injection molding material is injected so that a weld part at which the injection molding material converges is formed in a region not overlapping the plate material of the frame part.

A trim component for an interior of a motor vehicle has a film and has a carrier from a thermoplastic plastics material. The film has a relief structure, the carrier has a lattice structure having lattice members, and the carrier is back-molded on a rear side of the film such that the lattice members are connected in a materially integral manner to the rear side of the film.

A dissimilar material joint including a joined portion between a resin rib and a metal base, in which the metal base forms a protrusion protruding inside of the resin rib on at least a part of the joined portion.

A thrust reverser cascade of an aircraft engine comprises a frame and a vane overmolded onto the frame. The frame and the vane each comprise reinforcement fibers in a thermoplastic matrix. A method is disclosed for manufacturing the thrust reverser cascade or another part comprising an aerodynamic surface configured to interact with a flow of fluid. The method comprises providing a first portion of the part and overmolding a second portion of the part onto the first portion where the second portion includes the aerodynamic surface.

An apparatus, according to an exemplary aspect of the present disclosure includes, among other things, a body-in-white member having an inboard side and an outboard side, a reinforcing structure molded on the inboard side, and an energy absorbing structure molded on the outboard side. A method according to an exemplary aspect of the present disclosure includes, among other things, providing a body-in-white member having an inboard side and an outboard side, molding a reinforcing structure on the inboard side, and molding an energy absorbing structure on the outboard side.

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.

The present invention is intended to provide a method for manufacturing a resin gear with a core metal by which there is no reduction in strength even with gates allowing decrease in material costs such as pin gates in the molding die for injection molding. The manufacturing method includes: gates at a primary molding step and gates at a secondary molding step are pin gates or the like. The number of the gates at the primary molding step and the number of the gates at the secondary molding step are plural and identical, and the gates are arranged circumferentially. Gate positions G21, . . . at the secondary molding step are circumferentially intermediate or nearly circumferentially intermediate between gate positions G11, . . . and weld positions W11, . . . adjacent to the gate positions G11, . . . in the primary molded article.

A diffuser assembly includes a flexible diffuser membrane and a diffuser body. The flexible diffuser membrane defines a circumferential bead. The diffuser body defines a circular plate underlying the flexible diffuser membrane, and an edge ring covering a covered portion of the circumferential bead. The edge ring defines an inside surface that conforms to an outside shape of the covered portion of the circumferential bead. The edge ring is integral to the diffuser body. Such a diffuser assembly may provide a disposable diffuser assembly option with many advantages over conventional technologies such as improved ease of installation, lower weight, and lower cost.

A component for a vehicle interior is disclosed. The component may comprise a structural substrate comprising a fiber panel with at least one hole and a resin-formed structure; and a cover coupled to the fiber panel or the resin-formed structure. The fiber panel may be formed into a compression-formed component; the resin-formed structure may comprise a molded feature formed in the hole of the fiber panel. The resin-formed structure may reinforce the structural substrate. The fiber panel and the resin-formed structure may provide a substantially continuous structure. The resin-formed structure may extend along a surface of the fiber panel to form the resin-formed structure to the fiber panel. The cover may be applied to the fiber panel during compression molding. The component may comprise a trim panel, instrument panel, door panel, or other interior trim part. A method of manufacturing a vehicle trim component is also disclosed.

A method for forming a fiber-reinforced thermoplastic control surface includes forming first and second skins from a fiber-reinforced thermoplastic resin. The method further includes overmolding fiber-reinforced thermoplastic features onto the first skin and/or second skin, including stiffener structures, sidewalls, and/or hinges. The method further comprises welding or consolidating the first and second skins together, along with the associated internal features overmolded thereon to form a single-piece, stiffened, fiber-reinforced thermoplastic control surface.