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.

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.

An injection molding process method of a plastic part on a metal shell to form a high-strength combination comprises: forming a molding cavity which is inwardly concave from the outer surface and extending through flanges at periphery of the metal shell to area beneath bridges protruding from flanges, the bridges being removed after the injection molding. A plastic part with slight deformation is in the molding cavity and is tightly combined with the metal shell due to the bridges. The protruding bridges can be removed from the flanges by milling or cutting without damaging the plastic part, thus the plastic part does not require to be remachined, and the appearance of the metal shell is not affected.

A method of manufacturing an armour layer of a flexible pipe for transporting fluid from a subsea location and apparatus are provided. The method comprises winding a first length of composite tape to form a first section of the armour layer and positioning an end region of the first length of composite tape over an end region of a second length of composite tape to form an overlapping tape section. Heat and pressure is applied to the overlapping tape section to form a joined overlapping tape section in which the first length of tape is joined to the second length of tape such that the joined overlapping tape section has a lap shear strength of at least 11 MPa. The joined overlapping tape section and the second length of composite tape are wound to form a second section of the armour layer.

A method of manufacturing an armour layer of a flexible pipe for transporting fluid from a subsea location and apparatus are provided. The method comprises winding a first length of composite tape to form a first section of the armour layer and positioning an end region of the first length of composite tape over an end region of a second length of composite tape to form an overlapping tape section. Heat and pressure is applied to the overlapping tape section to form a joined overlapping tape section in which the first length of tape is joined to the second length of tape such that the joined overlapping tape section has a lap shear strength of at least 11 MPa. The joined overlapping tape section and the second length of composite tape are wound to form a second section of the armour layer.

Extruded molds and methods for manufacturing composite structures using the extruded molds are disclosed. The molds may include recessed or raised longitudinal features to impart a corresponding shape to the molded composite structures. The composite structures may be panels used to construct cargo vehicles, for example.

This extracting device 30 is for extracting a small and lightweight molded article 10 from a molding machine 20, and is provided with a first extracting member 40a, a second extracting member 40b, a first drive mechanism 50, and a second drive mechanism 60, wherein the first extracting member 40a and the second extracting member 40b are provided with accommodating portions 41a, 41b for accommodating the molded article 10, and shutter plates 42a, 42b for opening and closing the accommodating portions 41a and 41b.

High-frequency welding method for welding an accessory to a substrate by high-frequency welding machinery which includes a female mold, having a cavity formed by a profile having substantially the same shape and dimensions as the accessory, and a male mold, having a relief formed by a profile having substantially the same shape and dimensions as the accessory. The method includes: mounting the female mold on a movable upper plate of the machinery and the male mold on a fixed lower plate of the machinery, or vice versa, such that the profile of the cavity is aligned in a closure direction of the molds with the profile of the relief. The method further includes: positioning the accessory on the relief or in the cavity; positioning the substrate above the accessory; moving the upper plate towards the lower plate; supplying high-frequency welding energy to the upper plate and/or to the lower plate.

High-frequency welding method for welding an accessory to a substrate by high-frequency welding machinery which includes a female mold, having a cavity formed by a profile having substantially the same shape and dimensions as the accessory, and a male mold, having a relief formed by a profile having substantially the same shape and dimensions as the accessory. The method includes: mounting the female mold on a movable upper plate of the machinery and the male mold on a fixed lower plate of the machinery, or vice versa, such that the profile of the cavity is aligned in a closure direction of the molds with the profile of the relief. The method further includes: positioning the accessory on the relief or in the cavity; positioning the substrate above the accessory; moving the upper plate towards the lower plate; supplying high-frequency welding energy to the upper plate and/or to the lower plate.

A monolithic thermocasting system for thermocasting polymer and solid material and method of use having an internal frame system; an external frame system disposed external to the internal frame system; a mold cavity formed between the internal frame system and the external frame system, the mold cavity sized to receive the polymer and solid material and shaped to form an architectural member; a duct; and a heater element disposed in the duct for outputting thermal energy to the mold cavity to heat the polymer and solid material, the thermal energy being sufficient to thermocast the polymer and solid material to a combined building material.