Abstract: A method of making a natural fiber composite panel includes extracting bamboo fibers from bamboo and embedding the extracted bamboo fibers in a polymer matrix material. The bamboo includes bamboo fibers and lignin, and the step of extracting includes mechanically scraping the bamboo fibers to remove at least some of the lignin. In some cases, the bamboo is steamed, soaked in water, soaked in an acidic solution and/or soaked in an alkaline solution before mechanical scraping.

Abstract: A ultrasonic welding method of joining dissimilar-material workpieces, such as sheet materials, and the joined components formed thereby. The method includes applying ultrasonic energy to a thermoplastic piece to fill a hole of a dissimilar piece to form a weld point that is made up with polymer from the thermoplastic piece. In general, the geometry of the thermoplastic piece is not altered during the process. The dissimilar piece generally has a higher melting temperate and can be metal, thermoset polymers, or other thermoplastic material. The welded pieces can be arranged in a lap, laminate, or double lap configuration. In some embodiments, the hole of the dissimilar sheet material includes undercut features that improve the mechanical interlock between the dissimilar pieces. In some embodiments, the weld point has a mushroom cap to improve mechanical interlock.

Abstract: A fastener and method for joining dissimilar materials. The fastener has a metal body and a hollow portion. The method includes the steps of: layering a thermoplastic first component with a second component such that the first component covers an opening formed through the second component; pressing the metal fastener against the first component through the opening in the second component; and heating the thermoplastic at an interface of the metal fastener and the first component so that the thermoplastic flows into the hollow portion of the metal fastener during the step of pressing. A portion of the metal fastener is thus embedded in the thermoplastic and a joint is formed that attaches the first and second components together when the thermoplastic is cooled.

Abstract: A method of making a natural fiber composite panel includes extracting bamboo fibers from bamboo and embedding the extracted bamboo fibers in a polymer matrix material. The bamboo includes bamboo fibers and lignin, and the step of extracting includes mechanically scraping the bamboo fibers to remove at least some of the lignin. In some cases, the bamboo is steamed, soaked in water, soaked in an acidic solution and/or soaked in an alkaline solution before mechanical scraping.

Abstract: A reinforced composite panel and method of making the composite panel uses processed natural fibers such as bamboo along with a polymeric material. The method includes the steps of: treating a plant source comprising natural fibers with a solvent and processing the treated plant source. The processing step can include arranging the natural fibers into a sheet-like orientation in a variety of ways. A polymeric material is then applied to the natural fibers to form a composite sheet, and the composite panel can be formed from one or more composite sheets.

Abstract: A ultrasonic welding method of joining dissimilar-material workpieces, such as sheet materials, and the joined components formed thereby. The method includes applying ultrasonic energy to a thermoplastic piece to fill a hole of a dissimilar piece to form a weld point that is made up with polymer from the thermoplastic piece. In general, the geometry of the thermoplastic piece is not altered during the process. The dissimilar piece generally has a higher melting temperate and can be metal, thermoset polymers, or other thermoplastic material. The welded pieces can be arranged in a lap, laminate, or double lap configuration. In some embodiments, the hole of the dissimilar sheet material includes undercut features that improve the mechanical interlock between the dissimilar pieces. In some embodiments, the weld point has a mushroom cap to improve mechanical interlock.

Abstract: A fastener and method for joining dissimilar materials. The fastener has a metal body and a hollow portion. The method includes the steps of: layering a thermoplastic first component with a second component such that the first component covers an opening formed through the second component; pressing the metal fastener against the first component through the opening in the second component; and heating the thermoplastic at an interface of the metal fastener and the first component so that the thermoplastic flows into the hollow portion of the metal fastener during the step of pressing. A portion of the metal fastener is thus embedded in the thermoplastic and a joint is formed that attaches the first and second components together when the thermoplastic is cooled.

Abstract: A ultrasonic welding method of joining dissimilar-material workpieces, such as sheet materials, and the joined components formed thereby. The method includes applying ultrasonic energy to a thermoplastic piece to fill a hole of a dissimilar piece to form a weld point that is made up with polymer from the thermoplastic piece. In general, the geometry of the thermoplastic piece is not altered during the process. The dissimilar piece generally has a higher melting temperate and can be metal, thermoset polymers, or other thermoplastic material. The welded pieces can be arranged in a lap, laminate, or double lap configuration. In some embodiments, the hole of the dissimilar sheet material includes undercut features that improve the mechanical interlock between the dissimilar pieces. In some embodiments, the weld point has a mushroom cap to improve mechanical interlock.

Abstract: A reinforced composite panel and method of making the composite panel uses processed natural fibers such as bamboo along with a polymeric material. The method includes the steps of: treating a plant source comprising natural fibers with a solvent and processing the treated plant source. The processing step can include arranging the natural fibers into a sheet-like orientation in a variety of ways. A polymeric material is then applied to the natural fibers to form a composite sheet, and the composite panel can be formed from one or more composite sheets.