A jounce bumper of an automotive vehicle suspension system contains a longitudinal axis. The jounce bumper is configured to resiliently deform between an uncompressed state and a compressed state, where in the compressed state the jounce bumper has a smaller length in the direction of the longitudinal axis than in the uncompressed state. The jounce bumper also contains a base body that acts as a primary spring element, where the base body is partially or completely made of a volume-compressible first material. In particular, the base body further contains at least one secondary spring element integrated within the base body. The secondary spring element is resiliently deformable between a first length in the uncompressed state and a second length in the compressed state, where the second length is smaller than the first length. The secondary spring element is partially or completely made of a compact second material.

Two workpieces 30, 40 are joined by means of ultrasound. First, a workpiece 30 with at least one energy direction sensor 31 and a second workpiece 40 are provided. The workpieces are brought into contact with each other in such a way that the energy direction sensor 31 comes into contact with a first surface 41 of the second workpiece 40. Ultrasonic vibrations are then introduced into one of the workpieces 40 via a working surface 11 of a sonotrode 10. A sonotrode 10 is used, which has a contour with contact lines 12 on the working surface 11. The sonotrode 10 is positioned with respect to the first workpiece 30 in such a way that the contact lines 12 run transversely to the energy direction generator 31.

The invention relates a process for the preparation of a bonded structure (4) comprising at least a first plastic part (1) having a first bonding surface (1a), said process comprising the step of a) treating at least part of a first bonding surface of said first plastic part with a flame of a propane-comprising gas, said propane-comprising gas being propane or a mixture comprising at least 50 wt. % of propane based on the weight of the propane-comprising gas with one or more gases selected from the group consisting of methane, ethane, butane, pentane, and hexane, wherein, during treatment with a flame of the propane-comprising gas, a flame is produced by burning a mixture of air and the propane-comprising gas, wherein the gas-to-air ratio is chosen such that the propane gas to oxygen volume ratio is equal to or less than 1:5.01, for example less than 1:5.00 and preferably at least 3.50 to obtain a first plastic part having a flame-treated first bonding surface.

A welding apparatus is suitable for welding polymeric materials, and particularly but not exclusively those that may be thin or brittle. A welding apparatus is provided for welding polymeric materials along a weld zone of the polymeric material. The welding apparatus has a carrier for supplying heat to the weld zone to cause melting of the polymeric material, wherein the heating element is arranged to reciprocate relative to the carrier between a retracted and an extended configuration, such that as the element moves from the retracted to the extended configuration the heating element melts and penetrates the surface of the polymeric material. The carrier also has a trailing contact surface trailing the heating element along the weld zone arranged to constrain molten polymeric material in the weld zone. The heating element is also arranged to reciprocate relative to the trailing contact surface.

An additively manufactured structure and methods for making and using same. In a method for making the structure, a first layer structure can be formed. A second layer structure can be formed on the first layer structure and a support structure. The support structure can be removed from the second layer structure. The second layer structure can include an overhang structure that does not deform or break after the support structure is removed. The support structure can provide support to the second layer structure during printing. Strong bridging capability of the second layer structure is not required. The support structure can be quick and easy to make. The support structure can be reusable and does not add weight to the printed structure. The support structure can be easily removed after completing of printing. Installation of the support structure can be fast without significantly interfering with printing process.

An attachment part for connecting to a structural part. The attachment part has an attachment part longitudinal axis, and a weld portion to be welded to the structural part by torsional ultrasonic welding. The weld portion has a contact surface for contact with a torsion sonotrode, and a weld surface for connecting to the structural part. The weld portion is delimited, at least portionally, by an inner vibration decoupling zone. The inner vibration decoupling zone, at least portionally, surrounds an inner portion of the attachment part.

A method of manufacturing a unitary energy absorbing structure for a vehicle includes providing a first mold having a cavity receiving a first mandrel and a second mold having a cavity receiving a second mandrel. At least one mandrel segment is positioned in the first mold cavity and cooperates with the first mandrel. One or more layers of composite material at least partially cover the first mold cavity, first mandrel, at least one mandrel segment and second mold. The unitary structure is formed from the first layer, the second layer and the third layer of composite material with the first mandrel, the at least one mandrel segment and the second mandrel in the first mold and the second mold.

A method for producing components of an outer skin of a vehicle with a film, which is back-molded at least from one a front side or rear side with clear plastics material, includes subjecting the film to a thermoforming process in order to generate the desired three-dimensional form. The film is subjected to further steps for preparation of the back-molding, including providing the film at least partially with a color layer. The film includes regions, through which other colors are intended to show through and be visible from the front side, or electromagnetic waves are intended to pass. The film may be punched-out in the regions to define punched-out portion in which components are inserted. The components are attached to the film by adhesive and/or overmolding on the rear side.

The invention relates to a method for the ultrasonic welding of two plastic components using a sonotrode, wherein the energy for the welding is introduced into the plastic components via at least one or more pins of the sonotrode, wherein the two plastic components are welded to one another step by step, wherein the respectively subsequent step of the welding is carried out in a region which has already been loaded and relieved of tension as a result of the preceding step of the welding.

A component comprising a sheet-like reinforcing component having a first stiffness and a sheet-like attachment made of an attachment material having a second stiffness, wherein the first stiffness is higher than the second stiffness, wherein the planar reinforcing component has an upper and lower side and the attachment is connected at least to the upper or lower side of the planar reinforcing component in a first partial area of the planar reinforcing component.