Embodiments are directed to systems and methods for two or more cured composite assemblies that are bonded together to form a tubular composite structure, wherein each of the cured composite assemblies do not have a tubular shape. The tubular composite structure may form a spar for an aerodynamic component, for example. The two or more cured composite assemblies may comprise carbon or fiberglass composite materials or a combination of materials. Each of the cured composite assemblies may further comprise axial edges that are configured to be bonded to another of the cured composite assemblies, wherein the axial edges have a sloped shape. An adhesive agent may be applied on the axial edges for bonding two cured composite assemblies. Alternatively, or additionally, one or more fasteners may be used to attach the axial edges of at least two cured composite assemblies.

A method of manufacturing a hollow composite structure is provided. The method includes forming a first portion of the hollow composite structure having at least one open region and at least one wall, the at least one wall partially defining a hollow interior. The method also includes bonding a laminate shell to the first portion of the hollow composite structure proximate to at least one location of the wall to cover the open region and enclose the hollow interior. The method further includes disposing a second portion of the hollow composite structure over the laminate shell, the second portion comprising a plurality of plies. The method yet further includes curing the first portion and the second portion during a final cure.

An intake duct for an internal combustion engine includes a tubular wall configuring an intake passage. The wall includes segments that are separate from each other in a circumferential direction of the wall. At least one of the segments is made of a compression-molded fibrous body. Each of the segments includes a flange protruding radially outwards from the wall and having a joint. The joint of the flange of each of the segments and the joint of the flange of the corresponding one of the segments are joined to each other. Each of the flanges includes an opposing surface opposed to the corresponding one of the flanges. The opposing surface is provided with a step portion that is located closer to a proximal side of the flange than to the joint and forms a step in a thickness direction of the flange.

A disclosed example embodiment of a gauge wheel tire includes a first polyurethane sidewall portion, a second polyurethane sidewall portion, a polyurethane ground-engaging portion, and a polyurethane axial support portion. The first polyurethane sidewall portion is spaced apart from the second polyurethane sidewall portion, and the polyurethane ground-engaging portion extends from the first polyurethane sidewall portion to the second polyurethane sidewall portion and is adapted to contact a ground surface as the gauge wheel tire rotates about an axis of rotation. The polyurethane axial support portion extends from the first polyurethane sidewall portion to the second polyurethane sidewall portion, and is spaced apart from the polyurethane ground-engaging portion to form a gap that allows radial movement of the polyurethane ground-engaging portion relative to the polyurethane axial support portion.

A resin piping assembly including a base divisional component having first and second half components having respective first and second interfacial surfaces formed along an oil passage, and first and second divisional components which have respective third and fourth interfacial surfaces formed along the oil passage, and which are bonded to the respective first and second half components. Each of the base divisional component, and the first and second divisional components is formed of a resin material, and the first and second interfacial surfaces are spaced apart from each other, and open in respective opposite directions. The base divisional component further includes a cylindrical connecting pipe portion having a connecting passage portion which is a part of the oil passage and which is provided for communication between the first and second passage portions. Also disclosed is a process of forming the resin piping assembly.

A large tubular plastic tank is formed by fusion welding together half-shell parts at lengthwise flange joints to form a tubular body. Then, end caps are fusion welded onto the outermost ends of the tubular body and an assembly of two or more bodies. Electric or electromagnetic energy is used to melt in situ the fusion weld elements which are captured between the joining surfaces of the parts. A fusion weld element is secured beforehand to linear a joining surface of at least one of two mated tank parts. The weld element exits the joint between two lengthwise-mated parts at the location of mating tabs extending from the mated tank parts; the tabs are subsequently cut away. A circumferential flange joint is made by securing a fusion weld element to at least one joining surface of the mated tank parts, where the ends of the element run through holes in the faying surface of the flange.

The invention relates to a method for producing a fiber-composite hollow component from a fiber-composite material which contains at least one fibrous material and one matrix material, wherein the fiber-composite hollow component is formed from at least two fiber-composite half-shells which in a joining edge region of the fiber-composite half-shells are joined to one another such that a cavity is configured between the joined-together fiber-composite half-shells, wherein the method comprises the following steps: providing a first fiber-composite half-shell formed from the fibrous material of the fiber-composite material, and at least one second fiber-composite half-shell formed from the fibrous material of the fiber-composite material; assembling the first fiber-composite half-shell and the at least second fiber-composite half-shell so as to form the fiber-composite hollow component; wherein at least one spacer element is inserted in the joining edge region between the first fiber-composite half-shell and the at least second fiber-composite half-shell; incorporating an internal vacuum cover in the cavity formed by the assembling of the fiber-composite half-shells, and incorporating the assembled fiber-composite half-shells in an external vacuum cover such that a component cavity having the fibrous material of the fiber-composite hollow component to be produced is formed between the internal vacuum cover and the external vacuum cover; evacuating the component cavity having the fibrous material; and curing the matrix material which embeds the fibrous material of the fiber-composite half-shells, in order for the fiber-composite hollow component to be produced.

Disclosed is a method to form arbitrarily shaped, uniform, lightweight, thermally insulating and acoustically absorptive automotive components with controllable density, thickness, porosity, and surface integrity. The method is based on natural cellulosic fibers such as those found in cardboard and paper and uses a thermoplastic fiber and particle slurry to form fusible components. The method produces components having the benefit of commercially available thermoformed fiber mats or open-cell extruded foam components with excellent acoustical properties, enhanced thermal insulation, and are light weight, which limits engine inefficiency, and the high cost of such parts so as to allow large scale implementation.

An energy-absorbing assembly includes a first component and a second component. The first component includes a first polymer and a first plurality of reinforcing fibers. The first component includes a first peripheral wall defining a first interior compartment. A first interior portion of the first peripheral wall includes a first corrugated surface. A second component includes a second polymer and a second plurality of reinforcing fibers. The second component includes a second peripheral wall. A second interior portion of the second peripheral wall includes a second corrugated surface. The first corrugated surface is complementary to the second corrugated surface. The first corrugated surface is joined to the second corrugated surface.

A hot-plate-welded water pipe includes a first water inlet pipe, a second water inlet pipe, a lateral pipe, all of a hollow cylinder shape, and a cover plate. The lateral pipe is connected to and in communication with the first water inlet pipe and second water inlet pipe, an opening is provided on a central portion of the lateral tube, and the opening protrudes from a surface of the lateral pipe. The cover plate is connected onto the opening, and the cover plate is welded onto the opening through hot-plate-welding. The first water inlet pipe, the second water inlet pipe, and the lateral pipe formed integrally into a body through injection molding.