A process of making a drag-reducing aerodynamic vehicle system includes injection molding a body configured for attachment to a roof of a vehicle with a sliding core, wherein the body comprises an air inlet extending through a surface of the body, wherein the air inlet includes an air guide boss extending from an interior surface of the body, wherein the air guide boss adjusts an air stagnation point away from the windshield to reduce air pressure and drag on the vehicle; and ejecting the drag-reducing aerodynamic vehicle system from the injection mold using the sliding core.

A method for joining two objects by anchoring an insert portion provided on one of the objects in an opening provided on the other one of the objects. The anchorage is achieved by liquefaction of a thermoplastic material and interpenetration of the liquefied material and a penetrable material, the two materials being arranged on opposite surfaces of the insert portion and the wall of the opening. Before such liquefaction and interpenetration, an interference fit is established in which such opposite surfaces are pressed against each other, and, for the anchoring, mechanical vibration energy and possibly a shearing force are applied, wherein the shearing force puts a shear stress on the interference fit.

A method for joining two objects by anchoring an insert portion provided on one of the objects in an opening provided on the other one of the objects. The anchorage is achieved by liquefaction of a thermoplastic material and interpenetration of the liquefied material and a penetrable material, the two materials being arranged on opposite surfaces of the insert portion and the wall of the opening. Before such liquefaction and interpenetration, an interference fit is established in which such opposite surfaces are pressed against each other, and, for the anchoring, mechanical vibration energy and possibly a shearing force are applied, wherein the shearing force puts a shear stress on the interference fit.

To improve a method for ultrasonic welding of parts for vehicles and/or aircraft, a method in which an energy director made of non-woven fiber material is arranged between a first fiber composite part and a second fiber composite part to be joined together. A sonotrode is used to join/weld the parts together by pressing on the parts. The energy director is compliant such that a uniform even contact is generated between the first and second fiber composite parts during the welding process.

To improve a method for ultrasonic welding of parts for vehicles and/or aircraft, a method in which an energy director made of non-woven fiber material is arranged between a first fiber composite part and a second fiber composite part to be joined together. A sonotrode is used to join/weld the parts together by pressing on the parts. The energy director is compliant such that a uniform even contact is generated between the first and second fiber composite parts during the welding process.

Provided are a joining structure, a joining method, an exterior body for a wire harness, and a wire harness capable of firmly joining members having different physical properties while reducing the thickness of a joint part. The joining structure 10 joins a first member 1 made of a first resin and a second member 2 made of a second resin, wherein: the second resin has physical properties having a higher foaming ratio than the first resin; and a recessed joint part 3 is provided which reaches at least the inside of the first member 1 from the outer surface side of the second member in a state in which the first member 1 and the second member 2 are superimposed. Furthermore, a method for manufacturing the joining structure 10 comprises the steps of: superimposing a first member 1 made of a first resin and a second member 2 made of a second resin having physical properties having a higher foaming ratio than the first resin; and joining the first member 1 and the second member 2 by forming the recessed joint part 3 by pressing and hot-melting the second member 2 until the recessed joint part 3 reaches at least the inside of the first member 1 from the outer surface side of the second member 2.

Provided are a joining structure, a joining method, an exterior body for a wire harness, and a wire harness capable of firmly joining members having different physical properties while reducing the thickness of a joint part. The joining structure 10 joins a first member 1 made of a first resin and a second member 2 made of a second resin, wherein: the second resin has physical properties having a higher foaming ratio than the first resin; and a recessed joint part 3 is provided which reaches at least the inside of the first member 1 from the outer surface side of the second member in a state in which the first member 1 and the second member 2 are superimposed. Furthermore, a method for manufacturing the joining structure 10 comprises the steps of: superimposing a first member 1 made of a first resin and a second member 2 made of a second resin having physical properties having a higher foaming ratio than the first resin; and joining the first member 1 and the second member 2 by forming the recessed joint part 3 by pressing and hot-melting the second member 2 until the recessed joint part 3 reaches at least the inside of the first member 1 from the outer surface side of the second member 2.

There is provided a method for producing a metal-resin composite which includes a resin member and a metal member having a roughened surface in at least a portion of the surface thereof, the resin member being joined so as to be in contact with at least a portion of the roughened surface. The method includes a step of joining the resin member and the metal member by melting the resin member with the frictional heat generated in the surface of the metal member on its side opposite to the resin member in a state where the metal member and the resin member are superposed. The method includes making adjustment so that when the roughened surface is measured at arbitrary five points by using a confocal microscope according to ISO 25178, the developed area ratio (Sdr) is 5 or more in terms of number-average value.

There is provided a method for producing a metal-resin composite which includes a resin member and a metal member having a roughened surface in at least a portion of the surface thereof, the resin member being joined so as to be in contact with at least a portion of the roughened surface. The method includes a step of joining the resin member and the metal member by melting the resin member with the frictional heat generated in the surface of the metal member on its side opposite to the resin member in a state where the metal member and the resin member are superposed. The method includes making adjustment so that when the roughened surface is measured at arbitrary five points by using a confocal microscope according to ISO 25178, the developed area ratio (Sdr) is 5 or more in terms of number-average value.

The invention provides a sonotrode (100) for welding a material, the sonotrode (100) comprising a welding section (110) configured for contacting the material, wherein the welding section (110) defines a rounded shape (111) in a cross-section parallel to a longitudinal axis (A) of the sonotrode (100), wherein the rounded shape (111) approximates a circular sector (20), wherein the circular sector (20) has a central angle α.sub.c selected from the range of 25°-300°, and wherein the circular sector (20) has a central radius r.sub.c selected from the range of 5-30 mm, and wherein the sonotrode (100) has a width W perpendicular to the longitudinal axis (A) [and to the cross-section], wherein W is selected from the range of 10-100 mm.