Securing the second object to the first object

Abstract

According to one aspect of the invention, there is provided a method of mechanically fixing a first object (1) to a second object (2), the first object comprising a thermoplastic material in a solid state, the second object having a generally flat sheet having a perforation (20), the sheet having an edge (21) along the perforation, wherein the first object is positioned relative to the second object so that the edge is in contact with the thermoplastic material, and wherein mechanical vibrations are coupled into an assembly comprising the first and second objects until a flowing portion of the thermoplastic material becomes flowable due to frictional heat generated between the edge and the thermoplastic material and flows around the edge to at least partially embed the edge into the thermoplastic material. After the mechanical vibrations cease, the thermoplastic material is resolidified, whereby the resolidified thermoplastic material at least partially embedded in the edge anchors the first object to the second object.

Description

[0001] This application is a divisional application of PCT application PCT / EP2016 / 073422, which has application number 201680069402.4, application date September 30, 2016, invention name “Securing a second object to a first object” and priority date September 30, 2015, entering the Chinese national phase. Technical Field

[0002] The present invention relates to the field of mechanical engineering and manufacturing, in particular mechanical manufacturing such as automotive engineering, aircraft manufacturing, railway engineering, shipbuilding, machine manufacturing, toy manufacturing, construction engineering, etc. In particular, it relates to a method for mechanically fixing a second object to a first object. Background Art

[0003] In the automotive, aerospace and other industries, there has been a trend away from steel-only structures and towards using lightweight materials such as aluminium or magnesium sheet metal or polymers such as carbon fibre reinforced polymers or glass fibre reinforced polymers or unreinforced polymers, e.g. polyester, polycarbonate etc. instead.

[0004] New materials give rise to new challenges in bonding elements of these materials, in particular bonding a flat object to another object. An example of this is bonding a component of a polymer-based material to a metal component, such as a metal sheet.

[0005] To meet these challenges, automotive, aerospace and other engineering projects have begun to use adhesives in large quantities. Adhesives are light and strong, but have the disadvantage that it is impossible to control stability over a long period of time, because degraded adhesives, for example, are almost impossible to detect without completely releasing the adhesive due to brittle bonding. Adhesives can also lead to increased processing costs, both because of material costs and because of delays caused during processing due to the slow hardening process, especially if the surfaces to be connected to each other have a certain roughness and therefore cannot use fast-hardening thin layers of adhesive. In addition, a flat adhesive between two objects that do not have the same thermal expansion coefficient can cause additional stability problems, because the adhesive is routinely subjected to a large amount of shear forces due to temperature fluctuations.

[0006] A particular challenge when joining elements to one another is tolerance compensation, for example if the elements are joined to one another using other than adhesive joining, for example by screws and nuts or by pins. In such a joining, an exact definition of the relative position of the fasteners to the respective fastening locations is required. This exact definition is particularly difficult to achieve if the manufacturing process must be particularly economical and / or if the parts to be connected are relatively large in at least one dimension and / or react to the conditions to which they are subjected during the manufacturing process and are used in different ways (for example if they have different coefficients of thermal expansion). Summary of the invention

[0007] The object of the present invention is therefore to provide a method for mechanically fixing a second object to a first object, which overcomes the disadvantages of the prior art methods. In particular, the object of the present invention is to provide an economical method for forming a reliable connection between a thermoplastic component and a non-liquefiable component under conditions where the thermoplastic component is liquefied, or to form a reliable connection between different components by means of a thermoplastic connecting element. Another object of the present invention is to provide a method for forming a reliable connection between components that is effective and fast. Another object of the present invention is to provide a method for forming a reliable connection between components that allows effective tolerance compensation.

[0008] According to one aspect of the present invention, there is provided a method for mechanically fixing a first object to a second object, the method comprising the following steps:

[0009] - providing a first object comprising a thermoplastic material in a solid state;

[0010] - providing a second object having a substantially planar sheet with an edge;

[0011] - positioning the first object relative to the second object such that the edge is in contact with the thermoplastic material;

[0012] - coupling mechanical vibration energy into the assembly comprising the first object and the second object until the flow portion of the thermoplastic material becomes flowable due to frictional heat generated between the rim and the thermoplastic material and flows around the rim to at least partially embed the rim into the thermoplastic material;

[0013] - stopping the mechanical vibrations and allowing the thermoplastic material to resolidify, whereby the resolidified thermoplastic material at least partially embedded in the rim anchors the first object in the second object.

[0014] In the step of coupling mechanical vibration energy into the assembly, the first object may be pressed against the rim such that upon liquefaction of the flow portion the rim is pressed into the thermoplastic material of the first object.

[0015] After the mechanical vibrations have ceased, the pressure in embodiments is maintained until the flow portion has resolidified at least to some extent to prevent a spring-back effect.

[0016] In an embodiment, the second object is arranged to have a perforation of the sheet, wherein the edge extends along the perforation.

[0017] In the embodiment with a perforation, if vibrations are coupled into the first object, the sheet portion around the perforation has a protruding section protruding away from the sheet plane towards the first object, ie protruding proximally.

[0018] The first object and the connection with the second object can be in an embodiment such as a sealing perforation, ie sealing the proximal region of the second object from the distal region thereof. Thus the first object can for example have a continuation extending into a periphery which is embedded in the rim.

[0019] In other embodiments, the first object has a through opening, in which a connector or a non-liquefiable body described below can be arranged, which connector or non-liquefiable body forms an anchor for another object. It has, for example, threads or other engagement features, and / or it can be used for a nut and pin arrangement extending through it. Alternatively, a bearing sleeve, a ball bearing or other bearing can be positioned in the first object, in particular in the through opening of the first object.

[0020] In particular, mechanical vibration energy may be coupled into the first object but not (not directly, i.e. at least via the first object) into the second object. In particular, during the positioning step, the first object is typically brought into contact with the second object from the proximal side, and the step of coupling energy into the first object may comprise pressing the vibrating sonotrode against a coupling surface of the first object facing proximally, thereby coupling pressure relative to the second object and mechanical vibrations into the first object simultaneously via the sonotrode.

[0021] To apply a counter force to the pressure, the second object is then placed against a support, such as a non-vibrating support. In an embodiment, the second object is placed against the support without elastic or yielding elements between the support and the second object, so that the support rigidly supports the second object.

[0022] However, the pressure applied in the process can be low enough to enable the second object to be self-supporting. In general, the approach according to the invention gives very good energy absorption properties of the edge in physical contact with the thermoplastic object (acting as an inherent energy director for the mechanical vibration energy), the thermoplastic material and / or the edge being subjected to mechanical vibrations, so that it is already possible to apply only small pressures. This can be a significant advantage for applications in which at least one object has a complex shape and / or is part of a complex article (such as a car body), and therefore the rigidly supported support is placed in a lateral position where it is difficult to apply forces.

[0023] Nevertheless, coupling energy into the second object, ie applying mechanical vibration energy from the side of the second object, is not excluded.

[0024] In particular, but not exclusively, in embodiments comprising coupling vibrations into a second object, the vibrations may be transverse vibrations, whereas in other embodiments the vibrations may be longitudinal vibrations. Arrangements with transverse vibrations are known, for example, from the welding of metal parts. For this purpose, for example, the following options exist:

[0025] The sonotrode couples vibrations into the second object usually from the side (if defined in an in-plane direction relative to the sheet plane of the second object), whereas a separate pressure tool applies the required pressure between the first and second object.

[0026] - The sonotrode itself generates lateral vibrations at the distal end coupled to the second object. Thus, the mechanical coupling between the sonotrode and the second object enables this lateral movement to be transferred to the second object. For example, the second object comprises, in addition to (e.g. constitutes) the anchoring plate of the sheet, a fastening element that can be coupled to the sonotrode. In particular, in an embodiment, the second object is a fastening element configured to fasten another object to the first object, the fastening element having a corresponding mechanism, for example by being a threaded bolt (internal and / or external thread), a rod without a thread, a pin, a nut, a hook, an eyelet, a base for a bayonet connection, etc.

[0027] The present invention also relates to a set of sonotrodes and a set of second objects adapted thereto to implement a process according to any embodiment of the present invention comprising coupling mechanical vibrations into the second object. For example, the second object may include an anchoring plate and a fastening element bonded thereto, and the sonotrode may include a distal coupling output face shaped to contact the anchoring plate to transfer force and vibrations and a receiving structure for accommodating the fastening element. The receiving structure, such as a receiving opening or protrusion, may be adapted to mechanically engage a fastening structure (thread or the like) of the fastening element.

[0028] Alternatively, in addition to mechanical vibration energy, other energies may be coupled into the assembly. In one example, the second object may be preheated by infrared radiation, induction (particularly effective near the edge), hot air flow, etc. Additionally or alternatively, the thermoplastic material may be preheated locally at the interface near the edge, for example by electromagnetic heating as described in Swiss patent application 01104 / 15, by radiation, etc. For example, for electromagnetic heating as described in Swiss patent application 01104 / 15, electromagnetic doping may be provided for the thermoplastic material located in the attachment area.

[0029] In both cases, the preheating assists the process of making the thermoplastic material flowable, either directly or indirectly. An indirect effect is obtained if the preheating step results in an increased absorption of mechanical vibration energy at or near the point where the preheating step acts, in particular due to the increased internal friction caused by the increased temperature.

[0030] The purpose of this additional additional energy is to increase the speed and / or reduce the required pressure. This also has a positive effect on process control.

[0031] The flowing portion of the thermoplastic material is the portion of the thermoplastic material in the process and is caused to liquefy and flow due to the influence of the mechanical vibrations. The flowing portion is not necessarily a one-piece piece but may comprise components that are separate from each other.

[0032] The liquefaction of the flow portion is here mainly caused by the friction between the vibrating part (e.g. the first object) and the non-vibrating part (e.g. the second object) of the assembly, which directly or indirectly heats the thermoplastic material of the first object. This is particularly effective if the friction that generates the heat occurs where the material is to flow, because, contrary to other methods involving liquefied thermoplastic materials, there is no cooling effect where the flow portion has already flowed away from the heat source. In particular, in the step of causing the flow portion of the thermoplastic material to become flowable, the flow portion or a part thereof becomes flowable due to the heat generated between the protruding section and the thermoplastic material. In an embodiment, the second object is fixed to the first object due to the method steps described above, wherein the space on the other side of the second object than the side of the first object in contact with it (in embodiments of the type described above, the distal side, where the vibration energy is usually coupled into the first object from the distal side) is empty along the edge (thus if available, along the perforations), so that the thermoplastic material can immediately flow along the surface of the sheet of the second object. In particular, in an embodiment, no other object located on the distal side of the second object is fixed to the second object via the first object.

[0033] In an embodiment, the sheet portion along the edge (and therefore around the perforation if applicable) is deformed so that the sheet portion protrudes away from a defined sheet plane. In particular, the sheet portion may protrude towards the first object side (towards the proximal side in embodiments of the type described above, wherein vibration energy is typically coupled into the first object from the proximal side).

[0034] In particular, the protruding section, if present, which is a deformation section, may be the same metal sheet as the blade.

[0035] In this document, the term "sheet plane" means a plane / surface generally defined by the shape of the generally planar sheet in the region around the edge, especially around the perforations (if present). The sheet plane may be flat in the sense of extending directly in two directions. Alternatively, the sheet may be curved and thus formed into a more complex 3D shape, for example if it forms the surface of a complex object, such as the body of a car or aircraft. In examples where the second object is deformed near the edge to protrude away from the sheet plane, the curvature of the second object at the location from which the deformed section extends is often much greater than the curvature of the sheet plane.

[0036] This deformed section can be formed by deforming the corresponding part of the sheet, for example by making an incision (for example by stamping) and bending or other deformation so that the second element is opened, and the corresponding part of the sheet is initially located at the second element opening. Here, the deformed section can still be a single piece with the sheet.

[0037] As an alternative to a deformed section, it is also possible to provide a section of the sheet protruding away from the sheet plane as a separate element fixed to the sheet, for example by welding.

[0038] As a further alternative to the deformed section, the section protruding towards the side in contact with the first object can be manufactured by a forming process from scratch, which ends at the edge, for example if the section is ceramic, die casting or pressing or injection molding (followed by well-known subsequent processing steps). In this embodiment, the sheet can even be composed of a portion protruding towards the first object and / or a section embedded in the flow section after the process, i.e., it is not necessary to have a sheet plane further defined by the sheet.

[0039] In embodiments with a perforation and with a protruding (e.g. deformed) section around the perforation, the deformed section may be symmetrical, i.e. uniformly deformable around the perforation (this includes the possibility that the deformed section has a rough edge, e.g. with a sawtooth shape). In particular, it is rotationally symmetrical with respect to an axis perpendicular to the sheet plane passing through the center of the perforation.

[0040] Alternatively, it may be rotationally asymmetric about said axis, wherein the height of the protruding section varies as a function of the position along the edge. In this embodiment, the symmetry may be such that the protruding section does not extend all along the perforation but rather along a certain section of the edge where there is no protruding section. In this case, however, the protruding section may extend at least around more than 180% of the periphery, thereby locking the first and second objects to each other with respect to relative forces in all planes.

[0041] In a set of embodiments with a second object comprising a perforation extending along an edge, the sonotrode and the first object may be adapted to each other so that the coupling surface (the portion of the surface of the first object against which the sonotrode is pressed) covers the in-plane position of the edge but does not extend to a central position relative to the perforation. "Covering the in-plane position" in this context means within the protrusion along the proximal-distal axis, the edge being located within the region of the coupling surface.

[0042] For example, the coupling surface may form a trajectory about the center, with a central in-plane position corresponding to the in-plane position of the perforation.

[0043] Therefore, one or a combination of the following options may be implemented:

[0044] - the sonotrode comprises a central recess, having a coupling surface surrounding the central recess; and / or

[0045] The first object has a central recess facing the proximal side, with a coupling surface surrounding the central recess.

[0046] Effects of the coupling surface not extending to the central location may include making process control easier and / or preventing the central location of the first object (eg, having the functional element) from being damaged.

[0047] In a set of embodiments including a perforation of the second object and a protruding section around the perforation, the protruding section protruding toward the proximal side toward the first object, the first object may be provided with a spacer (also referred to herein as a "foot") facing distally. This space may be arranged laterally at the position where the contact side of the first object contacts the edge of the second object.

[0048] In particular, the space can be arranged more laterally than the protruding section of the second object, whereby, when the first and second objects are pressed towards each other, a relative movement of the first and second objects towards each other can be caused when a vibration is applied until the foot abuts against the sheet at a position defining the sheet plane. Thus, the z-position of the first object relative to the second object can be defined by the size of the foot acting as a spacer.

[0049] Thus, this foot is an example of a relatively simple measurement that accomplishes z-position control without complex measurement tools. In particular, the foot accomplishes good process control, wherein at the end of the process the operator gets physical feedback when the correct z-position has been reached. This is advantageous if the process is implemented manually, or equally if mechanical resistance is a control parameter in an automated process. Other methods for precisely controlling z-position are discussed below.

[0050] The method may comprise the further step of machining a perforation in the second body prior to the positioning step, for example by punching, drilling etc. Alternatively, in embodiments the perforation along which the edge is formed may be an opening which is anyway present in the second body or has been provided during machining.

[0051] The first object comprises a thermoplastic material. In an embodiment, the first object is composed of a thermoplastic material. In other embodiments, the first object comprises a body of non-liquefiable material in addition to the thermoplastic material. The body of non-liquefiable material may constitute a reinforcement portion of the first object.

[0052] In an embodiment with a non-liquefiable body, the body of non-liquefiable material is different from a filler that is just a large number of particles, but an enlarged body with a defined position and orientation and a large size. In the plane of the sheet defined by the second object, the size can be, for example, 10% of the average diameter of the first object (a cross section perpendicular to the insertion axis) or 10% of the average diameter of the perforations if applicable, and / or the characteristic size can be at least 0.1 mm in any direction. In particular, the body can be metallic or ceramic. In particular, the body can be, for example, of a defined shape and thereby increase the stiffness of the first object. By means of the body, the first object is confined within at least two spatially separated regions, namely a body region and a thermoplastic region.

[0053] In embodiments in which the first body contains a non-liquefiable material in addition to the thermoplastic material, the thermoplastic material may be arranged at least on the surface portion in contact with the rim.

[0054] The first object may include a fixing element that fastens another object to the second object. For example, the first object itself may be a fastening element (fastener) for this purpose by including an applicable structure such as threads or other applicable structures, or it may include a dedicated fixing element, such as a threaded rod, a nut, etc. In these embodiments, the first object may be shown as a fastener (or anchor) for another object. In alternative embodiments, the first object itself may constitute an object having a function other than being just a fastener.

[0055] In particular, but not exclusively, in these alternative embodiments, the first object may be relatively large and it may not be possible to vibrate the entire first object to attach the first object simultaneously at multiple attachment locations. In such embodiments, it may be necessary to cause multiple sonotrode actions simultaneously to attach and secure the first object to the second object at corresponding multiple attachment locations, and / or it may be advantageous to have sufficient flexibility to decouple portions of the first object from other portions of the first object at the locations where attachment occurs. Examples of such situations are discussed below, for example with reference to attachment flanges.

[0056] In an embodiment, the first object has an attachment zone containing a thermoplastic portion and also has a functional zone different from the attachment zone. This functional zone may, for example, include fastening structures and / or other fastening elements. This functional zone may be configured so that it is not possible and / or undesirable to locally liquefy the thermoplastic material that will be embedded in the edge during the process. In many embodiments, the first object located in the functional zone may contain a liquefiable material, but the function will be adversely affected by the process according to the invention.

[0057] In an embodiment, the first object is processed in a process comprising a two-color injection molding step, the attachment area is a thermoplastic material, and the functional area comprises another thermoplastic material. Subsequently (or also in other cases with a first object comprising thermoplastic material parts), the thermoplastic materials of different areas have different material properties.

[0058] - the elastic modulus E of the thermoplastic material of the functional area is greater, for example much greater, than the corresponding modulus of the attachment area; and / or

[0059] - The (elastic) extensibility of the thermoplastic material of the attachment zone is much greater than the extensibility of the functional zone. Therefore, the thermoplastic material of the attachment zone can optionally be an elastic thermoplastic material, such as thermoplastic polyurethane. It is thus suitable for repeated heating / cooling cycles. According to another option, the thermoplastic material of the attachment zone can be a partially crystalline polymer (such as polypropylene) with a relatively low glass transition temperature and a relatively high plasticity at elevated temperature through a one-time plastic deformation (creep) process to compensate for thermal distortions, such as during electrodeposition.

[0060] By means of the latter, different thermal expansion behaviors between the first body and the second body can be compensated.

[0061] In an embodiment comprising at least one attachment zone, the material of the (multiple) attachment zones may be secured to the first object body (enveloping the (multiple) functional zones) by a form-fitting connection. For example, the first object body may comprise at least one undercut opening, and the thermoplastic material forming the (multiple) attachment zones may be at least partially present within the (multiple) undercut openings. Additionally or alternatively, the body may comprise an open porous section having the thermoplastic material of the (multiple) attachment zones infiltrated within the porous section. In addition or alternatively to the form-fitting connection, other types of mechanical connections may also exist between the material of the attachment zone and the body, such as an adhesive connection.

[0062] In one set of embodiments, the first object comprises a body defining a functional area and a flange (attachment flange), the flange extending at least along a lateral periphery of a portion of the body and defining an attachment area, whereby at least a portion of the flange is clamped between the axially acting ultrasonic welding electrode and the second object during the step of coupling mechanical vibration energy into the assembly.

[0063] The attachment flange may be a peripheral, lateral protrusion of the first object. It may consist of a thermoplastic material; at least the distal side comprises a thermoplastic material. It may, for example, define a proximally facing coupling-in surface for a sonotrode, which is at least approximately parallel to the distal surface of the first object, the latter being in contact with the edge of the second object. Thus, even if the first object, due to its function, has a complex shape which may differ from a shape with a flat distal surface, less complex shapes become possible at the attachment site(s).

[0064] The first object, in particular its attachment flange, may comprise a well-defined, possibly proximally marked coupling surface portion, which is positioned to correspond to an attachment site defined by the second object, such as a perforation thereof, along which an edge extends. This coupling surface portion may, for example, be parallel to a corresponding distally facing surface portion on the opposite side, which contacts the edge of the second object.

[0065] Likewise, the first object may include an elastic connection between an attachment flange (or other attachment structure having a coupling surface and a surface portion in contact with the edge) and the main body of the first object, whereby the attachment structure (e.g., attachment flange) may be vibrationally decoupled from other portions of the first object.

[0066] This is an option in particular in embodiments in which the first object is relatively large and in which it is not possible to couple vibrations into the entire first object or in which this is disadvantageous. In this embodiment, the attachment at different attachment locations or for a number of attachment locations must be carried out simultaneously, in which case several sonotrodes must act simultaneously. Instead of sequential attachment at different attachment locations. Next, a certain flexibility of the first and / or second object is required, since the attachment process causes a relative movement of the first and second object at the actual attachment location, which movement, however, does not exist at the other attachment locations. An attachment flange and / or an attachment structure that is separated from the main body by a joint can bring about this flexibility.

[0067] In one set of embodiments, the method comprises the further step of providing the first and second objects with a connecting member that is initially separate from each other. In these embodiments, the component into which the mechanical vibration energy is coupled also comprises a connecting member. The connecting member may be caused to be at least partially embedded in the thermoplastic material of the first object during the process and to be anchored relative to the first and second objects after resolidification. In embodiments, as described in more detail below, the connecting member may be connected to the first object (by embedding or by further connection) in a plurality of possible relative positions, for example to compensate for dimensional and / or positional deformations during processing.

[0068] In particular, in the step of coupling mechanical vibration energy into the component, the vibrating sonotrode may be pressed against the coupling surface of the connecting element while the connecting element is pressed against the first object until the thermoplastic material of the first object becomes flowable at the edge of the connecting element so that the connecting element is driven into the first object. Simultaneously and / or sequentially, the mechanical vibration energy may also be absorbed at the interface of the second object and the first object.

[0069] The connector may hereby be caused to extend through a plane defined by the edge of the sheet and thus, if applicable, from its proximal side, defined by the entrance of the perforation. Similarly, in the case where the first object has a body of non-liquefiable material (such as a reinforcement), the body may be arranged to extend through a plane defined by the edge (if applicable, defined by the entrance of the perforation). More specifically, in embodiments where the second object has a perforation, the connector / body may extend through the perforation.

[0070] A connector of the type in question may consist of a non-liquefiable material. Alternatively, it may comprise a thermoplastic material. In one example, it comprises a thermoplastic material capable of being welded to the thermoplastic material of the first object; it may be the same thermoplastic material or at least a polymer material comprising the same matrix.

[0071] Connectors of the type in question may have one or a combination of the following functions:

[0072] - The connector may form with the thermoplastic material an interface where vibration energy absorption occurs. Thus, the connector provides an additional means to control energy absorption and thereby control the flow of the thermoplastic material.

[0073] The shape of the connection element may be designed to restrict the flow of the thermoplastic material, in particular inwardly with respect to the axial direction, in particular to induce a more pronounced flow of the material around the second body near the edge, in particular on its distal side.

[0074] The connector may have further functional elements, such as connection parts, flanges, etc. Generally, the considerations that apply herein to the shape and function of the connector also apply to the body of non-liquefiable material that is part of the first object (this body may be the connector shown pre-installed).

[0075] The main body of the non-liquefiable material of the first object or the connecting piece may carry structures for other functions, such as screws, other mechanical connections, contacts or leads, etc.

[0076] Regardless of whether a body or connector is present, in one set of embodiments the method comprises attaching the first object to a metal component forming part of a vehicle body.

[0077] In an embodiment, the body or the connecting element, respectively, has a surface provided with at least one retaining feature on a lateral surface portion, which retaining feature cooperates with the thermoplastic material of the body to stabilize the relative position of the body within the embedded thermoplastic material.

[0078] The invention also relates to a connection element having the characteristics defined herein.The invention also relates to a kit of at least one connection element and a first object and / or a sonotrode.

[0079] Furthermore, the invention relates to a connector which is a first object according to any embodiment described herein or which forms a part thereof. The invention also relates to a fastener which is a second object described herein and comprises a fastening element.

[0080] In one set of embodiments, the first object comprises a structured contact side of thermoplastic material, which contact side is the side of the first object that is in contact with the edge for fixing. The fact that the contact side is structured means that it is different from being just flat and uniform, and even and it comprises protrusions / recesses. For example, it comprises a pattern of ridges and grooves, such as a regular pattern.

[0081] It has been found that the structured contact side has the effect of reducing the energy and force input required until the edge has penetrated into the thermoplastic material of the first body to a sufficient depth. In particular, this required input may be reduced by more than a factor proportional to the unfilled recess volume fraction. This is due to the additional flow channels created by the structure.

[0082] In one embodiment, the structure forms a pattern of radially extending ridges / grooves.

[0083] In cases where the sheet of the second body has a protruding section which protrudes away from the sheet plane towards the contact side, the depth of the recess can be chosen to be smaller than the height of the protruding section.

[0084] Another set of embodiments also addresses the problem of reducing the required force and / or energy input. In this other set of embodiments, the second object comprises a plurality of, for example, smaller, peripheral perforations arranged around, for example, a larger main perforation.

[0085] The peripheral perforation can in particular be arranged in a section of the second body which protrudes away from the sheet plane of the second body towards the contact side, ie the peripheral perforation can be arranged at a position where the sheet is inclined relative to the sheet plane.

[0086] This peripheral perforation has the effect of increasing the footprint of the connection, providing additional fixation to rotation, reducing drag in the process by providing additional flow channels.

[0087] With reference to the embodiment groups discussed above, it is particularly desirable to reduce the input of energy and force if the materials involved are specialized and / or if the method is implemented at a relatively early stage in the processing of a complex object. For example, in embodiments where the second object may include a painted / painted piece of sheet metal, and the painted / painted piece may be destructible. The approach according to these embodiment groups may be advantageous in this case.

[0088] In many embodiments, if the method includes pressing the first object against the second object when vibrations are coupled into the first object, in particular, by holding the second object at a different location from the pressing location of the first object, such as a mounting frame, to generate a reaction force to the pressing force, or by making the second object part of a complex, relatively heavy object located on the ground. Then, in turn, the reaction force depends on the stiffness of the second object. If necessary, special supports can be used to assist.

[0089] In one set of embodiments, a dedicated anvil structure is used in addition to the second object. The anvil of this structure can be placed on the far side of the second object, and it can have at least one of the following functions:

[0090] - The anvil guides the flow and resolidification of the flowable thermoplastic material. Thereby, the overall stability of the connection between the first object and the second object is enhanced after the process, and this ultimately reduces the required penetration depth. Therefore, using the same anvil can be a method for reducing the required force and energy input.

[0091] The anvil can also support the second object and avoid undesired deformations thereof if, for example, the second object is relatively thin or weak.

[0092] This anvil is different from being merely flat. In particular, it may include a guide protrusion located outside the edge (if the edge extends along the perforation, then inside relative to the center of the perforation) and a recess located distally of the edge (and radially outwardly from the edge if the edge extends along the perforation) to guide the flow located "below" (distal) the edge and the second object portion adjacent to the edge.

[0093] The volume of this recess can be in particular smaller than the volume of available thermoplastic material that becomes flowable, so that if the vibration input is maintained long enough, the volume of the flowing portion is larger than the volume of the recess. Thus, a sufficient forming pressure can be built up during the process, so that the filling of the recess by the flowing portion is controllable and predictable.

[0094] In one set of embodiments, the method comprises adjusting the position of the first object and / or the sonotrode relative to the second object. This is in particular an xy (in-plane) position. There are two basic configurations for this:

[0095] In a first basic configuration, the xy position of the sonotrode relative to the second object is defined, for example by a mounting frame, and the adjusting step comprises adjusting the position of a first object arranged between the sonotrode and the second object relative to the sonotrode and the second object.

[0096] In a second basic configuration, the operator uses means for defining the position of the first object relative to the sonotrode, and the adjusting step comprises adjusting the position of the first object-sonotrode assembly relative to the second object.

[0097] According to a first basic configuration, the device for adjusting the position of the first object relative to the sonotrode and the second object (support or the like) is constructed independently of the sonotrode. Next, the operator must ensure that mechanical vibrations can be coupled into the first object. Therefore, according to a first option, the shape of the guide means used for this is adapted to the shape of the first object in such a way that only the lateral position is precisely defined, but a certain degree of freedom is left with respect to the movement in the axial direction (for the coupling into the longitudinal vibrations of the first object). According to a second option, which can be combined with the first option, the guide means comprises a spring, so that the first object is only loosely coupled to any mounting frame.

[0098] According to a second basic configuration, the sonotrode and the second object can be adapted to each other to define a lateral relative position. For example:

[0099] The sonotrode may comprise a guide protrusion cooperating with a guide recess of the first object, or vice versa. Optionally, this guide protrusion / guide recess (or other guiding means) differs from rotational symmetry to prevent any rotation of the first object relative to the sonotrode.

[0100] The sonotrode may comprise a peripheral flange surrounding the first object to define its position.

[0101] The sonotrode may comprise at least one penetration guide (a tip or the like) which penetrates into the material of the first object during the process.

[0102] It is also possible to temporarily fix the first object to the sonotrode, for example by means of screws or the like.

[0103] Additionally or alternatively, other means may also be used to temporarily join the first object to the sonotrode, such as using a vacuum between the sonotrode and the first object, for example by means of a suction channel passing through the sonotrode.

[0104] Additionally or alternatively, a separate guide may be used. This separate guide may be guided laterally both relative to the sonotrode and relative to the first object. In particular, it may be guided relatively loosely relative to the sonotrode so that vibrations are not coupled into the guide. This guide may be a cylindrical element guided in an aligned opening of the first object and the sonotrode, the opening being adapted to the cross section of the guide. In particular in embodiments in which the guide is also guided loosely relative to the first object, additional axial support may be provided to prevent the guide from loosening from the assembly.

[0105] If applicable, the cylindrical shape of this guide may be, but need not be, a rotating cylinder.

[0106] Additionally or even further alternatively, a clamping tool is used which is different from the sonotrode but is used in addition thereto. This clamping tool is used to press the first object against the second object at least in the initial phase of the step of coupling the mechanical vibration energy into the assembly. The problem is solved by this clamping tool, that when longitudinal vibrations are coupled into the first object from the sonotrode, wherein the sonotrode is pressed against the first object, the sonotrode does not exert any force on the first object approximately in half a waveform of each oscillation period. Without any lateral guide (such as described above), which could cause a loss of control, the first object is "unfixed" relative to the second object. The additional clamping tool ensures that the first object is pressed against the second object. This additional clamping tool may include a guide structure, such as a peripheral flange, which limits the lateral position of the first object relative to the guide tool.

[0107] The approach according to the invention has the essential feature that the attachment site defined by the edge of the embedded flow portion in the process does not have an exactly defined position, an exact positioning of the first object relative to the second object is desired and achievable.

[0108] More specifically, the change in the relative position of the attachment site and the first object can be accomplished using the following statements:

[0109] - The lateral (xy) variations depend greatly on the lateral extension of the first object or its attachment zone, respectively. For relatively small attachment zones (e.g. relatively small perforations), they may be, for example, between 0.1 mm and 5 mm. For larger attachment zones (e.g. larger perforations), they may be scaled up to larger values.

[0110] - If the first object has a flat distally facing surface, the axial (z-) variation depends on how far the second object's segment protrudes towards the first object. It can vary between 0.1 mm and 2 mm for relatively small protruding segment heights, and can be greater for larger sizes.

[0111] - Depending on the distance separating the different attachment sites, or more generally on the lateral extension of the attachment area, angular variations of up to 10° to 20° can be compensated.

[0112] In many embodiments, the limitation is given that around the attachment zone, the thermoplastic part that does not belong to the flow part should remain. The thickness of this non-liquefying zone is, for example, at least 1 mm in all directions.

[0113] Based on this fact, the method according to the invention can be used for tolerance compensation, for example by the following method:

[0114] Step 1: Measure tolerance mismatch, e.g. using visual methods and comparing with CAD data.

[0115] Step 2: Calculate the correct position x, y, z angle.

[0116] Step 3: Position the first and second objects relative to each other within the calculated correct position x, y, z angles (minus the z offset to account for the relative motion of the first and second objects during the following step 4).

[0117] Step 4: Implement a method according to any of the content and / or embodiments described herein until a correctly calculated position has been reached.

[0118] Optionally, the softness of the structure can be corrected by an external distance measurement system coupled to the means for applying the vibration energy, the correction system being adapted to the end z-position if necessary.

[0119] In an embodiment, additionally or alternatively, further measures for compensating for z variations may be used. By means of such measures, the range of z variations described above (e.g., between 0.1 mm and 2 mm) may be exceeded, and such measures also enable different types of control of z variation compensation.

[0120] Such additional measures include:

[0121] • An anchoring member and an adjustment member are provided, wherein at least the anchoring member belongs to the first object (and in an embodiment may consist of the first object).

[0122] · adjusting the z-position of the adjustment member relative to the anchoring member; and

[0123] When the adjustment member is in the adjusted position, fix its position relative to the anchoring member.

[0124] This z direction can be the direction perpendicular to the sheet plane defined by the second object at the edge of the attachment site. Alternatively, for example, if this plane is not defined, the z axis can be defined as the axis on which the pressing force acts during the step of applying mechanical vibrations for embedding the edge.

[0125] The following options can be implemented:

[0126] The fixing step may cause the adjustment component to be non-detachably fixed relative to the anchoring component. For example, the fixing step and / or the adjustment step may include applying mechanical vibrations to the assembly of the anchoring component and the adjustment component to cause the thermoplastic material of at least one component to become flowable to fix after resolidifying the components relative to each other.

[0127] οThis fixing of the parts to each other after resolidification can be caused according to the first option by the materials of the objects being fused together (for example in welding), or alternatively because the anchoring part and the adjustment part are one-piece with a transfer zone (collapse zone, extension zone) located between them that can deform when the thermoplastic material is flowable (here, flowable includes "paste-like", which is induced to plastic deformation by moderate force input).

[0128] o According to a second option, the components can be fixed to each other, wherein one component comprises a liquefiable material, in particular a thermoplastic material, and the other component comprises a structure that can be penetrated by the liquefiable material, whereby a positive connection is formed between the components after resolidification.

[0129] o In addition or as a further alternative, the components may be secured to each other by an adhesive connection between the resolidified material and the other material to which it is bonded.

[0130] - The conditioning and fixing steps may be combined in a single step process. For example, they may be implemented by a vibrating sonotrode that presses the parts against each other and, after the material has become flowable, moves the parts relative to each other until the desired z position has been reached, while stopping the movement and the energy input (depending on the configuration, the energy input may have been stopped for a period of time before the desired position has been reached). After resolidification, the resolidified flowable material fixes the relative position. Optionally, the bearing force may be maintained during resolidification.

[0131] - Alternatively, the adjustment step may be performed before the fixing step. Next, for embodiments including fixing by inputting mechanical vibration energy, the anchoring component and the adjustment component may be configured so that their relative z position is temporarily locked so that the combined action of mechanical vibration and pressure does not change the relative z position. For example, the anchoring component and the adjustment component may have threaded portions that cooperate so that the adjustment component can be threadedly connected to the anchoring component. Other configurations may also be used for this temporary locking. As an alternative to this temporary locking, the mechanical vibration may be coupled into the component from a direction that is not parallel to the z-axis but, for example, substantially perpendicular to the z-axis.

[0132] For example, initially, measurement data on details of the second object (or assembly comprising the second object) and / or details of any other components (the first object, other objects to be fixed to the first object) may be obtained. Based on this, the desired z adjustment may be pre-calculated.

[0133] o The alternative of performing the adjustment before the fixing can be used for a separate step in the process. The production line then comprises an adjustment station and a fixing (fastening) station. In particular, this can be advantageous if the second object is relatively large or belongs to a relatively large pre-assembly (e.g. a car body), because then the z adjustment step can be carried out at a smaller station and does not delay the main process.

[0134] The adjustment part can be a connection piece or a body of the type described above.

[0135] - Alternatively, the anchoring member may comprise a connection piece or a body of the type described above, the adjustment member being optionally another object, ie configured to be fixed in an adjustable position relative to the connection piece / body.

[0136] According to another embodiment, both the adjusting member and the anchoring member contain thermoplastic material and the adjusting member and the anchoring member are welded to each other.

[0137] As yet another embodiment, the anchoring member and the adjusting member are in one piece but have a collapse zone or an extension zone between them, which zone is activated by energy input.

[0138] If the anchoring member and the adjusting member are not in one piece, the method may comprise, prior to the adjusting step, positioning the adjusting member relative to the anchoring member.

[0139] The adjusting step may be performed after the step of fixing the first object to the second object and / or simultaneously.

[0140] Unless stated otherwise, these possibilities can be combined at will.

[0141] In embodiments including fixing and / or adjusting by mechanical vibration energy input, the fixing and / or adjusting can be implemented together with fixing the first object to the second object according to the first option. Alternatively, positioning and / or adjusting the components relative to each other can be implemented after fixing. As yet another alternative, as described above and as discussed in more detail below, fixing and / or adjusting the components relative to each other can be implemented before fastening.

[0142] Optionally in any case, the step of coupling mechanical vibration energy into the component in order to fix the edge of the embedded second object and the step of coupling mechanical vibration energy into the component for fixing and / or adjusting may include pressing the vibrating sonotrode against the component in a direction that is not perpendicular to the z-axis but, for example, in a direction parallel to the z-axis or at a certain angle thereto.

[0143] In a first subgroup that complements this option, the pressures applied for tightening and for fixing / adjusting have the same direction. In a second subgroup, they have opposite directions.

[0144] In any case, during the steps of coupling energy into the assembly and pressing the vibrating sonotrode against the coupling surface to fix the first object to the second object, a portion of the second object may define a stop surface for movement of the first object relative to the second object during the fixing process. After the first object has come into contact with the stop surface, the mechanical resistance to further movement is greatly increased. The relative position of the first object and the second object is thereby defined, and when pressure and mechanical vibrations are subsequently coupled into the assembly for fixing and / or adjustment, the relative position of the first object and the second object will still remain defined.

[0145] This stop surface can be limited, for example, by a flat part of the second object surrounding the attachment site / sites.

[0146] The method of adjusting and fixing at an adjustment position described above can be implemented in the embodiment of the aspect of the invention described here. However, it can also be implemented independently thereof.

[0147] The invention also relates to a device comprising an anchoring member and an adjustment member as described with reference to any embodiment of the method mentioned herein.

[0148] In one set of embodiments with or without a step for adjusting the z-position, the second object comprises an extended opening (in contrast to a perforation, along which the edge caused to be embedded in the thermoplastic material extends). The first object (and / or the connecting element fixed thereto) can then extend through the entrance of this opening. Thereby, there is more space and in particular a greater depth available for functional components of the first object and / or the connecting element, respectively.

[0149] The second object does not need to protrude along the extension opening towards the side of the first object and does not need to have any other shape particularly suitable for the fixing / fastening step. Likewise, the dimensions of the functional component / connector can be selected because of the available space of the extension opening.

[0150] In this set of embodiments, the first object has an extension portion extending through the entrance of the extension opening.

[0151] The connector may be configured to also extend through the entrance of the opening and to be fixed relative to this extension. In particular, the connector can be fixed at different depths, in particular it is an adjustment component with a relative z-position in the above sense. Likewise, the movement of the connector into the extension is not necessarily co-linear with the movement during the fixing process, so that adjusting the z-position comprises adjusting the z' position with the z' axis at a certain angle to the z axis. In summary, the parameters that can be used to fix the connector relative to the first object become independent of the anchoring process due to the extension opening.

[0152] In some embodiments including an extension opening and a connector, the connector is configured to allow another object to be fixed thereto. Thus, a binding element may be provided to fix the other object, especially if the other object has a relatively large extension in two in-plane directions. For example, in this embodiment, the other object may be clamped between the connector and the head of the binding element.

[0153] A coupling element of this type can, for example, be clipped or screwed to the connection piece, or be fixed by a bayonet-type connection or the like, or be fixed thereto by a material connection (glued connection, welded connection, fusion connection, etc.).

[0154] Also in this set of embodiments, the dimension of the extension opening is larger than at least one in-plane dimension of the extension portion, whereby xy position adjustment of the functional component and / or the connector relative to the second object becomes possible.

[0155] In an embodiment, the extension portion comprises a tube portion extending into the opening, whereby the connector may be at least partially placed within the tube portion.

[0156] Embodiments of the second object comprising an extended opening may comprise a plurality of perforations of the type discussed above, in particular perforations around which the second object has a side facing the first object (the proximal side if vibrations are coupled into the first object, the distal side if vibrations are coupled into the second object). Such perforations may in particular be distributed around the periphery of the extended opening.

[0157] In this embodiment or other embodiments with a plurality of perforations, the first object may in particular be of a type comprising an attachment region (e.g., an attachment region for each perforation) and a functional region. In particular, the first object may be a dimensionally stable material, such as a metal, a composite, a ceramic, etc., except for the attachment region(s) comprising a thermoplastic material.

[0158] Embodiments comprising extended openings are particularly suitable for such arrangements, i.e., where the second object, the first object and / or, if applicable, the further object are not flat in the sense of extending directly in two directions, but have a complex 3D shape. This is because the extended openings provide an additional degree of freedom for the connection, in particular with a connector, which can be extended into space and to directions that are not restricted by the geometry of the location where the fastening takes place (e.g., around a perforation of the type described above).

[0159] In alternative embodiments, if the dimensions allow for this, the first object may have an extension that extends into the perforation of the second object and through the plane of the sheet (if defined). A separate extension perforation is then not required. Also in these embodiments, the extension of the first object may have an attachment structure for securing the additional object. This attachment structure may include threads, snap-fit ​​structures, adhesive structures, an extendable material area for self-tapping threaded engagement, etc.

[0160] Embodiments of the methods and uses of the apparatus described herein include a combination of the securing means described herein and the use of an adhesive.

[0161] In particular, if two objects are to be fastened to one another by means of an adhesive, the waiting time until the adhesive connection is sufficiently strong and the lack of stability of the connection often become a problem, a problem which is all the more serious if the adhesive connection and therefore the part where the adhesive is applied must be relatively thick, for example so that the connection has the necessary residual flexibility to compensate for different thermal expansion behaviors if necessary. Similarly, if the adhesive has an additional sealing function, a thick layer of adhesive is necessary in many cases. One-component or two-component polyurethane adhesives are often used for this purpose.

[0162] According to a first option, the combination of fixing according to the invention and applying adhesive can therefore comprise positioning the objects to be connected, applying adhesive (before or after positioning) and fixing the objects to each other by the fixing method described herein.

[0163] According to a second option, in addition to the mechanical connection caused by the fixing means described herein, a portion of the adhesive is used as a sealant.

[0164] According to another aspect of the present invention, there is provided a method of providing an anchor at a desired xyz position relative to a second object, the method comprising the steps of:

[0165] - providing a first object comprising a thermoplastic material in a solid state;

[0166] - providing a second object comprising an attachment site, the attachment site comprising an edge of non-liquefiable material;

[0167] - positioning the first object relative to the second object to provide an assembly comprising the first and second objects, wherein within the assembly the attachment site is in contact with the thermoplastic material;

[0168] - when the attachment site is in contact with the thermoplastic material, coupling mechanical vibration energy into the component until the flow portion of the thermoplastic material becomes flowable and at least partially embeds the edge into the thermoplastic material;

[0169] - stopping the mechanical vibration and allowing the thermoplastic material to resolidify, whereby the resolidified thermoplastic material at least partially embedded in the rim anchors the first object within the second object,

[0170] - providing an anchor configured for anchoring a further object relative to said second object,

[0171] - adjusting the position of the anchor relative to the body of the first object; and

[0172] - fixing the anchor relative to the body of the first object when the anchor is in the adjusted position.

[0173] Here, the anchor may be an adjustment component of the type described above.The body of the first object (first object body) may be the first object or a component of the first object fixedly fastened to the second object.

[0174] The options discussed above for securing the first object to the second object and for adjusting the adjustment position of the adjustment component also apply in this regard.

[0175] In particular, the fixing step and / or the adjusting step may include applying mechanical vibrations to the assembly of the anchor and the body of the first object to cause the thermoplastic material in the body of the first object or the anchor or both to become flowable and, after resolidification, to fix the anchor and the body of the first object to each other.

[0176] The present invention also relates to the use of the method described and claimed herein to attach a first and a second object to each other, wherein the second object has at least one attachment point, in particular a plurality of attachment points, which are composed of a (e.g. deformed) part that defines an edge and faces a part of the first object, and wherein the first object tolerance for positioning the attachment point on the second object is greater than the tolerance corresponding to the final positioning of the first object relative to the second object.

[0177] The present invention further relates to a method for mass-producing a plurality of components, each component comprising a first object fixed to a second object, wherein the second object comprises at least one attachment site, wherein a standard positioning offset of the attachment sites between different components is greater than a standard position offset of the objects located between the different components relative to each other (and / or the position of one of the objects relative to a third object to which the other object is fixed) (the standard offset corresponds to a relative average value).

[0178] Another set of embodiments relates to a further object being reversibly fastened to a second object by means of a first object. "Reversibly fastened" in this context means that the further object can be fastened to the second object and can be removed therefrom multiple times without any irreversible operation (such as breaking, melting, etc.).

[0179] More specifically, another object is provided, which includes at least one connector portion for removably connecting a first object thereto, such as by a clamping connection. The method according to this embodiment includes securing the first object to the second object by the method described herein.

[0180] In a particular subgroup of this group, in which the inventive approach has particular advantages, relates to situations where the further object has a plurality of connector parts to be fastened to a second object at a plurality of positions. According to the prior art, a plurality of locating connectors for a detachable clamping connection have to be attached to an object having a flat surface (the second object in the present terminology) at positions corresponding to the positions of the corresponding connector parts of the movable further object. The challenge here is that, in order for the clamping connection to work correctly, the position of the locating connector parts must be very precise. This requirement is in practice difficult to meet in a cost-effective process.

[0181] In the embodiment of the subgroup described herein, this problem is solved by providing a first object for each fastening position. The first object or, if available, a connector of the type discussed above is fixed to the corresponding connecting portion of another object by a reversible connection. A corresponding number of perforations of the second object are provided at a position almost corresponding to the first object. Next, the formation described herein is implemented for each first object, and the first object or connector is fastened to the corresponding connecting portion. If the material of the object is flexible enough, this can be completed by each first object in turn. Alternatively, all or some of the first objects can be fixed to the second object at the same time.

[0182] The relative positioning of the perforations of the first and second objects does not need to be very accurate and can vary within the tolerances given by the dimensions of the first object relative to the dimensional tolerances of the perforations without adversely affecting the fixation. The positioning of the fastening locations (perforations and deformation sections) relative to the positioning of the connecting portion of the further object is therefore looser than with prior art methods. However, due to the fact that the first object is attached to the further object during the fixation process, the positioning of the detachable clamping connection is precisely fixed.

[0183] In another set of embodiments, the first object is used as a connector for fixing the third object to the second object, especially if the third object has a flat portion similar to the second object and the components of the second and third objects are accessible from one side. For example, the second and third objects may be metal objects or fiber composite objects, or one of them may be a fiber composite object and the other a metal object. In particular, the second and third objects may be different materials having substantially different thermal expansion coefficients α.

[0184] According to the prior art, this connection is mainly obtained by blind rivets or by gluing. Blind rivets are technically more complex. In addition, both blind rivet and gluing connections have the basic characteristic that they have very limited adaptability to compensate for shear loads if the connected objects react differently to temperature changes due to different thermal expansion coefficients. For example, the thermal expansion coefficient of aluminum is 2*10 -5 K, however, the thermal expansion coefficient of a typical CFK (carbon fiber reinforced composite material) may even have the opposite sign: α CFK =-5*10 -6K. For example, in industrial processes, subassemblies are often subjected to a cathodic electrodeposition (or other immersion bath) process after assembly processing, which is simply produced at an elevated temperature of, for example, about 180° C. Thus, in industrial processes, objects are subjected to an electrodeposition process after being assembled to one another and will be fixed to one another by (blind) rivets in addition to being joined by an adhesive connection. When subjected to temperature changes, for example during the electrodeposition process (if applicable) or during use under changing ambient conditions, this will lead to deformations around the rivet connection and thus to permanent internal stresses and / or bearing stresses, depending on the arrangement also to delamination, etc.

[0185] The approach according to the present invention provides a solution to this problem.

[0186] Thus, the second object is arranged distally of the third object and the third object is provided with a through opening, in particular with a through opening having a larger diameter than the through hole of the second object, the edge being formed along the through hole of the second object. The step of positioning the first object relative to the second object comprises causing a distal portion of the first object to pass through the opening through the third object until the edge comes into contact with the thermoplastic material. After the step of coupling vibration energy into the assembly, the thermoplastic material, having flowed around the edge, will have a portion distally of the second object, which portion, after resolidification, can be shown as forming a foot of the first object, which here becomes a blind rivet.

[0187] Furthermore, in embodiments where both the second and third objects have defined attachment sites, the need for precise positioning is low.The fact that the flowable part flows in the process ensures that any deviations etc. are compensated for by the thermoplastic material flowing through.

[0188] Typically, the diameter of the distal portion (or shaft) of the first object will be approximately equal to or smaller than the diameter of the opening of the third object, but will be larger than the diameter of the perforation, so that when pressed in a distal direction relative to the second object, the first object will encounter resistance from the second object. This will result in liquefaction at the interface between the second and first objects when the first object is subjected to mechanical vibration.

[0189] In this set of embodiments, the first object is provided with a head (or perhaps the head is formed during the process). The step of coupling mechanical vibration energy into the assembly is then carried out until the distally facing shoulder formed by the head abuts the proximally facing surface of the third object around the entrance of the opening, which step then includes pressing the first object distally relative to the second object (and also the third object).

[0190] In a subgroup of this set of embodiments, the thermoplastic material of the first object is selected to have a glass transition temperature less than the temperature reached during the subsequent electrodeposition process, for example 180° C. or 185° C., but has a melting temperature significantly higher than this electrodeposition temperature. Thus, when the assembly is heated to the electrodeposition temperature, the thermoplastic material is in a rubbery, flexible state that allows significant deformation (creep), the material having a very high stretchability to deform without failure, so that different thermal expansion coefficients can be compensated by controllable temporary deformation of the thermoplastic material. If in an embodiment the glass transition temperature is greater than room temperature, the thermoplastic material and therefore the connection will automatically harden again when the assembly is cooled to the temperature at which it is used. In an embodiment, if the ability to compensate for thermal deformations is important, the thermoplastic material of the first object can be selected as a thermoplastic elastomer at least at the attachment site.

[0191] In this group of embodiments, the first object may in particular have a body of a non-liquefiable material. In particular, this body may form the core of the shaft portion. Optionally, if applicable, the body may also form the head. If the body forms the core of the shaft portion, the body shaft portion may optionally have an axial extension sufficient to extend through the perforation. The diameter of the body shaft portion may then be approximately equal to the diameter of the perforation, or it may be smaller or larger than this, and when the first object is once again pressed against the second object, a further deformation of the second object around the perforation will then be caused.

[0192] In this context, the word "diameter" does not necessarily mean that the corresponding structure (perforation, opening, shaft cross section, etc.) needs to be circular, although circles are often chosen, especially because they are easier to process. In case the corresponding structure is not circular, "diameter" means the average diameter, unless otherwise stated.

[0193] In embodiments, particularly (but not limited to) this set of embodiments, if the first object has a body of a non-liquefiable material, then the body can be configured to pierce the second object to form a perforation. For example, the distal piercing tip or punching blade can initially contact the second object, apply a punching force, and optionally couple mechanical vibration energy or other energy into the first object. Next, or already in this perforation step, the thermoplastic material contacts the edge created by the perforation step and (simultaneously or subsequently) becomes flowable when energy input begins.

[0194] In this set of embodiments, the sheet is deformed around the perforation to protrude distally, i.e. away from the side of the first object in contact with it and away from the third object. However, it is also possible to provide a second object that is substantially flat around the perforation or even protrudes proximally into the opening of the third object.

[0195] A further set of embodiments also relates to fixing a further third object to the second object via the first object. According to this further set of embodiments, the third object has a substantially flat sheet similar to the second object, the sheet having an edge. Optionally, the third object sheet may have a third object perforation, with an edge extending along the perforation.

[0196] For example, in this further set of embodiments, the second and third objects both comprise (or consist of) metal sheets, which may be the same material or different materials, and which form corresponding edges.

[0197] For this further set of embodiments, the step of coupling mechanical vibration energy into the component includes coupling mechanical vibration energy into the assembly including the first, second and third objects until the flowing portion of the thermoplastic material becomes flowable due to frictional heat generated between the edge and the thermoplastic material and flows around the edge to at least partially embed the edge into the thermoplastic material and flows around the third object to embed the third object edge into the thermoplastic material, whereby after the step of stopping the mechanical vibration, the re-solidified thermoplastic material embeds the (second object) edge and the third object edge to fix the second and third objects relative to each other, whereby the second and third objects are fixed to each other. The flowing portion does not necessarily have to be continuous here. Instead, the flowing portion optionally has a sub-portion that becomes flowable when in contact with the second object edge and the third object edge, respectively, with the non-flowable portion of the first object located between them.

[0198] In this other group of embodiments, the second object edge and the third object edge are both formed into a shape which is different from a simple straight edge and has at least one bend or rounded corner. This is for example the case if the corresponding edge extends along a perforation. For example, the second object and the third object both have perforations, have corresponding edges along the perforations, and have the option of the perforations being arranged approximately coaxially after the positioning step. By means of corresponding geometric shapes, a connection which prevents relative rotation or connection at the corners can also be achieved.

[0199] Instead of extending along the perforation, the edge (or at least one of the second and third object edges) may extend along a peripheral portion of the corresponding object, which peripheral portion forms a corresponding curved structure or a structure with rounded corners, such as a wavy structure or the like.

[0200] By being curved or having rounded corners, the shape of the edge gives the connection additional stability, in particular with respect to shear forces along the plane of the sheet.

[0201] In a first subgroup of this further group of embodiments, the second and third objects are in contact with the first object from opposite sides during the positioning step, i.e. the first object is clamped between the second and third objects, e.g. the second object is arranged such that the edge is in contact with a generally distally facing surface of the first object and the edge of the third object is in contact with a generally proximally facing surface of the first object. The second and third objects are thus anchored from opposite sides of the first object.

[0202] In the first subgroup, the mechanical vibrations can be coupled into the assembly via the third object or the second object, the other of these objects and / or the first object abutting against a non-vibrating support. Alternatively, the mechanical vibrations can be coupled into the third object and the second object. Additionally or alternatively, the vibrations can be coupled directly into the first object, the second and third objects being pressed against the first object from opposite sides.

[0203] In a second subset of embodiments, the second and third objects are in contact with the first object from the same side. Here, the edges of the second and third objects are adjacent to each other and extend approximately parallel in embodiments. For example, if the edges extend along corresponding perforations, the perforations of the second and third objects may have different diameters and be arranged approximately coaxially.

[0204] In this second subgroup of embodiments, the mechanical vibrations are coupled into the component by being coupled into the first object. It is also possible to couple the vibrations directly into the second and / or third object. In the latter case, an intermediate element, such as a polymer, can be placed between the sonotrode and the corresponding object (e.g. silicone, PTFE, etc.).

[0205] In embodiments, optionally but not necessarily, wherein vibration energy is coupled into the component via the second object (and / or, if applicable, via the third object) (the sonotrode), the first object via which the vibration is coupled into the component and the vibrating tool (the sonotrode) conform to each other so that, in addition to the contact surface between the tool and the second / third object, there is a contact surface between the tool and the first object, wherein in the step of coupling vibration energy into the component, the thermoplastic material of the first object is caused to become flowable at the interface with the tool and is caused to flow relative to the tool.

[0206] For example, the first object may include at least one protrusion protruding from a corresponding surface, toward which the edge of the second / third object is pressed. If the deformation section along the edge is deformed to protrude toward the first object, the protrusion may in particular protrude beyond the sheet plane from the plane defined by the distal edge. This protrusion is at least partially rendered flowable under the effect of vibration energy and is caused to flow, in particular to fill gaps and provide another aid to the fixation.

[0207] In addition or as an alternative to the first body comprising protrusions, the sonotrode may comprise protrusions in order to produce the contact surface.

[0208] The invention also relates to an arrangement for implementing the invention. The arrangement encloses a first object of thermoplastic material in a solid state, a second object having a generally flat sheet, wherein the sheet has an edge, the first object and the second object being positionable relative to each other to provide an assembly comprising the first and second objects, the edge being in contact with the thermoplastic material within the assembly, the arrangement optionally further comprising a sonotrode capable of coupling mechanical vibration energy into the assembly, and / or optionally further comprising a connector of the type described herein. Additionally or alternatively, the arrangement may include a membrane interface between the sonotrode and the corresponding object, for example as an intermediate sheet of the type described above.

[0209] More generally, components of the arrangement may have the properties described with reference to the various embodiments of the methods taught herein.For example, the sheet may have perforations with edges extending along them.

[0210] The invention also relates to a reinforcement portion or a connection element having the characteristics described herein.

[0211] Furthermore, the invention comprises an object as described with reference to another object of the special subgroup mentioned above, i.e. an object comprising a plurality of connecting parts and, for each connecting part, a first object comprising thermoplastic material, the shape of the first object being designed to be removably / reversibly fastened to the corresponding connecting part.

[0212] Typically, the first and second and, if applicable, the third object are construction parts (construction elements) in the broad sense of the term, i.e. elements that can be used in any field of mechanical engineering and construction, such as automotive engineering, aircraft construction, shipbuilding, building construction, machine construction, toy construction, etc. Typically, the first and second objects and the connecting element, if applicable, will all be man-made, hand-made objects. It is therefore not excluded that natural materials, such as wood-based materials, are used in the first and / or second object.

[0213] The second object may be any object having a flat sheet. "Sheet" does not necessarily mean a uniform thickness here. The second object may in particular be a metal sheet. Alternatively, the second object may be another object having a sheet, for example a more complex object having a portion of a metal sheet, which portion constitutes the sheet, or wherein the sheet does not consist of a metal sheet in the narrow sense of the term (produced by rolling), but is, for example, a metal part produced by a casting process, such as a die casting.

[0214] Returning to the thermoplastic material of the first object, in this context the expression "thermoplastic material capable of being made to flow, for example, by mechanical vibrations" or simply "liquefiable thermoplastic material" or "liquefiable material" or "thermoplastic material" is used to describe a material comprising at least one thermoplastic component, which becomes liquid (flowable) when heated, in particular when heated by friction, i.e. when arranged on one of a pair of surfaces (contact surfaces) in contact and vibratingly moving relative to each other, wherein the frequency of the vibrations has the properties as discussed above. In certain cases, for example if the first object itself has to carry a large amount of load, it may be advantageous if the elastic modulus of the material is greater than 0.5 GPa. In other embodiments, the elastic modulus may be lower than this value, since the vibration-conducting properties of the thermoplastic material of the first object do not play a role in this process. In special embodiments, the thermoplastic material therefore even comprises a thermoplastic elastomer.

[0215] Thermoplastic materials are well known in the automotive and aerospace industries. For the purposes of the method according to the invention, known thermoplastic materials that are particularly suitable for use in these industries can be used.

[0216] Thermoplastic materials suitable for use in the process according to the invention are solid at room temperature (or at the temperature at which the process is carried out). It preferably comprises a polymeric phase (particularly based on C, P, S or Si chains) which is converted from a solid state to a liquid or flowable state above a critical temperature range (e.g. by melting) and which is converted back to a solid when cooled again below the critical temperature range (e.g. by crystallization), whereby the viscosity of the solid phase is several orders of magnitude (at least three orders of magnitude) higher than the viscosity of the liquid phase. Thermoplastic materials will generally comprise polymer components which are not covalently crosslinked or crosslinked, the crosslinking bonds being reversibly opened when heated to or above the melting temperature range. The polymer material may also comprise fillers, such as fibers or particulate materials, which are not thermoplastic or have thermoplastic properties comprising a melting temperature range which is significantly higher than the melting temperature range of the base polymer.

[0217] In this context, a "non-liquefiable" or "non-liquefying" material is generally a material that does not liquefy at the temperatures reached during processing, and therefore in particular at the temperature at which the thermoplastic material of the connector liquefies. This does not exclude the possibility that a non-liquefiable material can liquefy at a temperature not reached during the process, which is generally much higher than the liquefaction temperature of the thermoplastic or the temperature at which the thermoplastic is liquefied during the process (e.g. at least 80°C). The liquefaction temperature is the melting temperature of crystalline polymers. For amorphous thermoplastics, the liquefaction temperature (also referred to herein as the "melting temperature") is the temperature above the glass transition temperature at which the thermoplastic becomes sufficiently flowable, sometimes referred to as the "flow temperature" (sometimes defined as the lowest temperature at which extrusion is possible), for example the temperature at which the viscosity of the thermoplastic drops to less than 10 4 Pa*s (in embodiments, especially for polymers that are substantially free of fiber reinforcement, is less than 10 3 For example, the non-liquefiable material may be a metal such as aluminum or steel, wood or a hard plastic, such as a reinforced or unreinforced thermosetting polymer or a reinforced or unreinforced thermoplastic material, which has a melting temperature substantially higher than the melting temperature / glass transition temperature of the liquefiable part, for example having a melting temperature and / or a glass transition temperature at least 50° C. or 80° C. or 100° C. higher.

[0218] "Melt temperature" herein is sometimes used to refer to the liquidus temperature at which a thermoplastic material becomes sufficiently flowable, ie, the conventionally defined melting temperature for crystalline polymers and a temperature above the glass transition temperature at which a thermoplastic material becomes sufficiently flowable for extrusion.

[0219] Specific examples of thermoplastic materials are: polyetherketone (PEEK), polyesters such as polybutylene terephthalate (PBT) or polyethylene terephthalate (PET), polyetherimide, polyamides such as polyamide 12, polyamide 11, polyamide 6 or polyamide 66, polymethyl methacrylate (PMMA), polyoxymethylene or polycarbonate polyurethane, polycarbonate or polyester carbonate, or acrylonitrile butadiene styrene (ABS), acrylate-styrene-acrylonitrile (ASA), styrene-acrylonitrile, polyvinyl chloride, polyethylene, polypropylene and polystyrene, or copolymers or mixtures of these.

[0220] In addition to the thermoplastic polymer, the thermoplastic material may also include suitable fillers, for example reinforcing fibers, such as glass fibers and / or carbon fibers. The fibers may be short fibers. Long fibers or continuous fibers may be used in particular for the parts of the first and / or second object that are not liquefied in the process.

[0221] The fiber material, if present, may be any known fiber reinforcement material, in particular carbon, glass, Kevlar, ceramics such as mullite, silicon carbide or silicon nitride, high strength polyethylene (Dyneema), and the like.

[0222] Other fillers which do not have a fibrous shape are also possible, such as powder particles.

[0223] Mechanical vibrations or oscillations suitable for embodiments of the method according to the invention preferably have a frequency between 2 and 200 kHz (even more preferably between 10 and 100 kHz, or between 20 and 40 kHz), and a vibration energy between 0.2 and 20 W / mm2 of active surface.

[0224] In many embodiments, in particular embodiments involving coupling of vibrations into the first object, the vibrating tool (e.g., ultrasound) is designed, for example, so that its contact surface oscillates primarily in the direction of the tool axis (proximal-distal axis, corresponding to the axis along which the first and second objects move relative to each other under the influence of energy input and possible forces when the edge is caused to penetrate into the material of the first object; longitudinal vibration) and with an amplitude between 1 and 100 microns, preferably in the range of 30 to 60 microns. Such preferred vibrations are generated, for example, by ultrasonic devices known in ultrasonic welding.

[0225] In other embodiments, the vibration is a transverse vibration, i.e. an oscillation at an angle to the proximal-distal axis, e.g. perpendicular to the proximal-distal axis and thus, e.g. parallel to the contact surface between the first and second objects. The vibration energy and amplitude are similar to the parameters of the longitudinal vibration described above.

[0226] In another group of embodiments which can be shown as a subset of embodiments with transverse vibrations, the oscillations can be rotational oscillations, i.e. the vibrating object vibrates in a torsional movement back and forth. In order for rotational oscillations to be an option, the second object should not have a rotationally-proof geometry, where for example an edge extends circularly around a perforation. Again, this type of oscillation is particularly suitable for arrangements in which the first object is relatively small, in particular it is or belongs to a connection.

[0227] Depending on the application, the vibration power (more specifically: the electrical power by which the sonotrode transducer is powered) may be at least 100 W, at least 200 W, at least 300 W, at least 500 W, at least 1000 W, at least 2000 W.

[0228] In this document, the terms "proximal" and "distal" are used to indicate direction and position, ie, "proximal" refers to the side of the combination where the operator or machine applies the mechanical vibration, while "distal" is the opposite side.

[0229] The contact side of the first object and the second object is sometimes referred to herein as the "contact side." In embodiments where the first object is disposed proximally of the second object and vibration is applied to the first object pressed against the second object, the contact side is distal and includes a distally facing surface against which an edge of the second object is pressed. BRIEF DESCRIPTION OF THE DRAWINGS

[0230] In the following, embodiments of the present invention and embodiments are described with reference to the drawings. The drawings are schematic. In the drawings, the same reference numerals represent the same or similar elements. The drawings show:

[0231] Figure 1a and Figure 1b is an embodiment of a second object having a fixed position;

[0232] Figure 2a and Figure 2b It is a substitute for the second object;

[0233] Figure 3a-Figure 5b are cross sections of different configurations at the initial stage of implementing the method and after the method has been implemented;

[0234] Figure 6-Figure 8 are different embodiments of the connector;

[0235] Fig. 9 and Fig.10 is another alternative construction;

[0236] Figure 11-13 It is an alternative sonotrode design;

[0237] Figure 14a-Figure 14c is an embodiment of reversibly fixing another object to a second object by means of a first object;

[0238] Figure 15-16 are other configurations for implementing the present invention;

[0239] Fig.17a and Fig.17b is yet another second object having a fixed location including a plurality of perforations;

[0240] Fig.18a and Fig.18b are structures of an initial stage and a final stage of fixing a third object to a second object via a first object, respectively;

[0241] Figure 19-22 Is used for basic Fig.18a and Fig.18b A different first object of the configuration shown;

[0242] Fig.23 and Fig.24 is a variation of this construction;

[0243] Fig.25a and Fig.25b Another configuration of an initial stage and a final stage of fixing a third object to a second object via a first object, respectively;

[0244] Fig.26 yes Fig.25a A variation of the construction of;

[0245] Figure 27-Figure 29 It is a variation of the characteristics of the sheet along the edge;

[0246] Fig.30 Another configuration is an initial stage of fixing a third object to a second object via a first object;

[0247] Fig.31 is another configuration of the first object and the second object;

[0248] Fig.31a Yes Fig.31 a variation of the first object of the construction;

[0249] Fig.32 and Fig.33 is another configuration in which the third object is fixed to the second object via the first object;

[0250] Fig.34a and Fig.34b It is a different edge structure;

[0251] Fig.35a and Fig.35b are different variations of the construction;

[0252] Fig.36 and Fig.37 It is another alternative structure;

[0253] Fig.38 It is a flow chart;

[0254] Fig.39 It is a structure with elastic seals;

[0255] Fig.40 is used for Fig.39 Flowchart of the construction;

[0256] Fig.41 It is another construction with an elastic seal;

[0257] Fig.42 and Fig.43 is another structure for fixing the third object, the second object and the first object to each other;

[0258] Fig.44 It is the principle that the second object has multiple attachment sites;

[0259] Fig.45a and Fig.45b The second object has a plurality of attachment sites, wherein the attachment sites collectively lock the first object relative to the second object in all in-plane directions;

[0260] Fig.46 It is the principle of tolerance compensation;

[0261] Fig.47 The minimum depth is shown to be dependent on the angle;

[0262] Fig.48 is a configuration with a second body having a sheet plane that is not perpendicular to the axial direction and also illustrates the principle of angular imbalance compensation;

[0263] Fig.49 is a first object having a functional area and an attachment area;

[0264] Fig.50a and Fig.50b is a structure for guiding the first object during a processing step;

[0265] Fig.51 is by attaching the support in the manner according to the invention;

[0266] Fig.52 is a snap-on connector attached by means according to the invention;

[0267] Fig.53 It is vibration decoupling;

[0268] Fig.54 is an embodiment having a mold casting a second object;

[0269] Figure 55-Figure 56 A structure having an anchoring component and an adjusting component;

[0270] Fig.57a and Fig.57b are anchoring components and adjustment components of other embodiments;

[0271] Figure 58a-Figure 58c is another embodiment of an anchoring component and an adjusting component and details thereof;

[0272] Figure 59-Figure 60 is another configuration of a first object, an adjustment member, and a second object, wherein the first object serves as an anchoring member;

[0273] Fig.61a and Fig.61bIt is the form of the second object and the first object at different stages of regulation;

[0274] Figure 62-Figure 63 is a configuration in which the connecting member is used as an adjusting member;

[0275] Figure 64a and Figure 64b is a configuration in which the connector has a gradually inclined portion that matches the gradually inclined opening at different stages;

[0276] Fig.65 is another configuration in which the connector is used as an adjustment member;

[0277] Figure 66-Figure 68 is an insert that can be used as a connection piece or as part of a regulating component that also includes a liquefiable material;

[0278] Fig.69 and Fig.70 It is an attached flange with a flexible joint;

[0279] Fig.71 It is an attachment flange with a dedicated coupling surface portion;

[0280] Fig.72 is a first object having different thermoplastic material components;

[0281] Figure 73-Figure 76 It is a construction that realizes the principle of providing structure to the contact side;

[0282] Figure 77-Figure 79 is realized Figure 73-Figure 76 Different cross sections of the protrusions of the first object of the illustrated principle;

[0283] Fig.80 and 81 A configuration having a second object, the second object having a main perforation and a plurality of peripheral perforations;

[0284] Figure 82-Figure 84 is a structure having a second object, the second object having a symmetrical deformation section;

[0285] Fig.85 and Fig.86 It is the principle that the first object with the spacer controls the z position;

[0286] Figure 87-Figure 91 A structure that realizes the principle of limiting the coupling surface between the ultrasonic welding electrode and the first object to a region designed to be in the shape and position of the second object;

[0287] Fig.92 and Fig.93 There are two basic configurations used to adjust the position within a plane;

[0288] Fig.94 and Fig.95 yes Fig.92 Examples of basic constructions;

[0289] Figure 96-Figure 102 yes Fig.93 Examples and principles of basic construction;

[0290] Fig.103 is a fastener as an example of a second object;

[0291] Figure 104-106 It is the principle of coupling mechanical vibrations into a second object;

[0292] Fig.107 It is a two-station production line;

[0293] Figure 108-Figure 110 is the design and construction of a sonotrode for coupling lateral vibrations into a second object; and

[0294] Figure 111-113 is a configuration in which the second object has an extended opening;

[0295] Fig.114 and Fig.115 is a first configuration having an anvil;

[0296] Figure 116-118 is another configuration with an anvil;

[0297] Fig.119 and Fig.120 is a structure having a first object, the first object having an attachment structure; and

[0298] Fig.121 is a flow chart including a method for adjusting position. DETAILED DESCRIPTION

[0299] Figure 1a and Figure 1b A metal sheet 2 is shown as an example of a second object in a top view and in a cross section. The metal sheet comprises a perforation 20, for example made by a perforating tool. The perforation is prepared, for example, by slowly pressing a tool with a tip against the metal sheet, while the metal sheet rests against a support having an opening at the location where the tool acts, until the tip of the tool penetrates. The shape of the perforation will be irregular, with a plurality of tongues. Alternatively, the shape may be regular if the corresponding geometric shape has been punched out or cut out (by water jet or laser) before or during a previous sheet forming operation. The metal sheet forms an edge 21 around the perforation 20, which has the function of an energy guide in a subsequent step. In Figure 1bThe following parameters are shown: height h, (average) diameter d of the perforation, diameter D of the segment deformed to protrude from the plane of the metal sheet (in some cases it is best to define it to be larger than the diameter d of the perforation), angle α defined here as the angle between the deformed segment and the perpendicular to the plane of the metal sheet; corresponding definitions are used throughout this article.

[0300] As an alternative to irregular perforations, by means of suitable perforating equipment (eg using a laser) in combination with a pre-cut center hole geometry, one can also process irregular or regular shapes, such as shown in FIG. 2a and Figure 2b Circular perforations shown.

[0301] See also Figure 3a and Figure 3b , describing the basic principles of many embodiments and specific embodiments of the method according to the present invention.

[0302] The first object 1 comprises a thermoplastic material. In the embodiment shown, the first object is shown to have a plate-like section consisting of a thermoplastic material and defining a proximal facing side 11 serving as the mentioned coupling surface and a distal facing side 12 in contact with the protruding section around the perforation 20 when the first object is positioned relative to the second object 2. However, in more general cases, the first object 1 may have other shapes and have a non-uniform material composition. Some examples are shown in the embodiments described below.

[0303] More generally, the first object may be a component to be connected, or a portion of a component to be connected, or a connecting member (pin, clip base, rivet, etc.).

[0304] If the first object itself is the component to be connected (as many components in mechanical engineering and manufacturing include a portion of thermoplastic material), the inventive approach has the following advantages in addition to the usual advantages of the invention (low-cost assembly and components, reliable anchoring, possible tight sealing connection):

[0305] o the position relative to the first object may generally need to be defined with much less precision and therefore with significantly greater tolerances than would be required if fastened by a fastener matching a well-defined fastening structure, and

[0306] o Fewer parts and fewer assembly steps are required.

[0307] If the first object is a separate connecting element, then, in addition to the usual advantages, the method according to the invention offers considerable flexibility in the choice of the shape and properties of the connecting element, for example also in conjunction with the following reference Figure 14a-Figure 14c The method described has the further advantage of having smaller tolerances than prior art methods.

[0308] In order to fix the first object to the second object, the vibrating sonotrode 6 presses the first object against the second object around the perforation 20. The mechanical vibration energy coupled into the first object is thereby propagated through the first object and absorbed at the locations where the first object is in contact with the edge 21, which thus acts as an energy director. The thermoplastic material around the edge is thus heated and becomes flowable, allowing the protruding section of the sheet to be pressed into the body of the first object. After resolidification, this results in at least the protruding section being anchored in the first object and thereby forming a mechanical form-fitting connection between the first object and the second object. Figure 3b The resulting arrangement is shown.This figure schematically shows the material portion 14 which has flowed underneath the second object and thus caused the mentioned anchoring.

[0309] In one set of embodiments, the material flow to the underside of the second object is aided and / or directed by a suitably shaped anvil structure. This principle can be used in any embodiment of the invention that allows access to the fixed position from the far side, i.e., the side opposite to the side on which the ultrasound waves are applied, including embodiments described with reference to other figures not shown herein that are not explicitly shown in the drawings. Fig.114 The anvil structure is schematically illustrated in FIG. The anvil 600 is used to support the second object during the fixing process. The anvil 600 is different from being just a flat surface, but includes a guide protrusion 601 and a receiving recess 602 around it. Fig.115 As shown by the arrows in , the guide protrusions 601 help to secure the thermoplastic material located distally to the second object and thereby increase the overall stability and reduce the required penetration depth.

[0310] exist Figure 4a and Figure 4b In the embodiment shown, the first body 1 is not plate-shaped but stud-shaped. In addition to the portion 15 of thermoplastic material, it also has a reinforcement 16 whose material is not liquefiable under the conditions applied during the processing. In particular, this reinforcement can be metal. In the embodiment shown, the reinforcement 16 is a bushing, which optionally has threads or other structures that allow further elements to be fixed thereto. Figure 4b In particular, it can be seen that this reinforcement 16, in addition to another function (e.g., as mentioned, suitable for fixing further elements thereto), can also bring additional mechanical stability to the connection between the first object and the second object. For example, as shown in the configuration, it can extend into the perforation and thus stabilize the connection between the first object and the second object with respect to shear forces that may act thereon.

[0311] Another function of the reinforcement 16 is to assist in controlling the flow of the thermoplastic material by forcing the thermoplastic material to flow distally and laterally. Fig.114The anvil described has a similar function, with the difference that its position does not need to be approached from the distal side.

[0312] In some similar Figure 4a / Figure 4b In one embodiment, it is advantageous to ensure that mechanical vibrations are not coupled directly into the reinforcement, thereby preventing any situation where the thermoplastic material around the reinforcement is liquefied and the position of the reinforcement is thus unstable. Therefore, the shape of the first object and the sonotrode can be designed so that the coupling surface is limited to the area around the reinforcement, as described below, for example with reference to Figures 87- Fig.91 Description.

[0313] In one set of embodiments the method comprises the further step of providing a further connecting member 3 which is initially separate from the first and second objects and which is assembled with the first and second objects in the fixing method to form an integral assembly. Figure 5a An example of such a connecting piece 3 is shown. The connecting piece has a distal tip and a retaining structure 31 along the lateral periphery in the described embodiment. Prior to the step of coupling mechanical vibration energy into the first object, the ultrasonic welding electrode 6 is used to couple energy and pressure into the connecting piece, thereby driving the connecting piece into the first object 1, wherein the material of the first object locally liquefies by absorbing the mechanical energy at the point of contact with the connecting piece 3. Once the proximal end face of the connecting piece 3 is flush with the proximal side 11 of the first object 1, the step is carried out according to reference Figure 3a and Figure 3b The description continues. By suitable ultrasonic welding electrode design (see, for example, the following description Fig.11 and Fig.12 ), the depth to which the connecting element is driven into the assembly comprising the first and second objects can be set. The retaining structure will be penetrated by the liquefied and resolidified thermoplastic material in the assembled state, so that they bring additional mechanical stability. Figure 5b The components after the process are shown.

[0314] The connector 3 may have a similar function to a reinforcement of the type described above, and the teaching herein relating to the properties of the reinforcement also applies to the connector, and vice versa, the main difference being that the reinforcement is initially part of the first object before coupling energy into the arrangement, as opposed to the connector.

[0315] Figure 6 , Figure 7 and Figure 8 Variants of the connecting element 3 (or of the reinforcement) are also shown. Figure 6 The connecting piece 3 has an attachment wedge 32 on which another element can be clamped. Optionally, after the fixing process, it can be connected with the following reference Figure 14a-Figure 14cThe described fastening clip has a similar function, with the difference that the part to which the further element is clamped is part of the connecting piece 3 (or the reinforcement) and not part of the thermoplastic part.

[0316] For the process using the connecting piece 3 of FIG. 3 , an annular ultrasonic welding electrode (tubular ultrasonic welding electrode; see below) is used. Fig.13 ) is advantageous so that the attachment wedge 32 does not come into direct contact with the ultrasonic welding electrode.

[0317] As Figure 5a Another difference of the embodiment, which is unrelated to the attachment wedge, is that the distal end does not have a tip but instead has a distally facing edge 33 that has a similar function to the tip, but will affect material flow control by increasing the propensity of the thermoplastic material to flow in the distal direction, which may be desirable or undesirable depending on the assembly situation.

[0318] Figure 7 An embodiment of the connecting element 3 is a bushing with an internal thread 39 and an external retaining structure 31 .

[0319] exist Figure 8 In the embodiment of the invention, the connector has, in addition to the distal tip 36 and the retaining structure 31, a head 34 (independent of these) with a proximally facing flange 35 that helps control the flow of the thermoplastic material. In particular, it prevents the thermoplastic material of the first object 1 from flowing to the sides at a more proximal position, thereby forcing it to flow to the position where the second object 2 is arranged, thus helping to form a more obvious mechanical fixation.

[0320] Reference Fig. 9 , shows a similar principle but with a flange portion 18 made of the thermoplastic material of the first body - again this will at least initially form a flow control to prevent lateral flow. Combination with a non-thermoplastic flange attached to the thermoplastic material of the first body is possible, for example.

[0321] exist Fig.10 In a variant example, the first object 1 has a reinforcement portion 16, but it protrudes proximally from the proximal end face of the thermoplastic portion 15, whereby the first object is designed so that the reinforcement portion 16 moves relative to the thermoplastic portion 15 during the process, whereby the thermoplastic material of the thermoplastic portion 15 is displaced.

[0322] If the reinforcement itself is a plastically deformable material, then Fig.10 Next, the distal portion of the reinforcement 16, for example Fig.16The distal foot portion shown is deformed outwards under the effect of the pressure caused by the thermoplastic material located distally thereto and thereby increases the anchoring strength. Here, the reinforcement itself can be a thermoplastic material, which allows mechanical vibrations and pressure to be at least partially transmitted through the reinforcement, while the reinforcement 16 is still deformable. For example, for this purpose the reinforcement can be a thermoplastic material with a higher liquidus temperature than the material of the thermoplastic portion 15, or a material based on the same polymer but with a higher filler level and thus a higher viscosity. Alternatively, it can be a bendable metal, in which case the portion to be deformed must be correspondingly thin enough.

[0323] The deformation process of the reinforcement portion 106 is particularly important in the anvil ( Fig.10 assisted by a support member (not shown), the anvil having, for example, a Fig.114 A central guide protrusion 601 is shown.

[0324] Fig.11 , Fig.12 and Fig.13 An alternative sonotrode design is shown. Fig.11 The sonotrode 6 has a distal peripheral flange 61 which, depending on the configuration, can either restrict the lateral flow of the thermoplastic material, or press the reinforcement / connector into a depth different from the surrounding material of the reinforcement / connector, or both.

[0325] Fig.12 The distal protrusion 62 of the sonotrode 6 can have a guiding function, for example together with a guiding recess of the first object or the connecting element, and / or can have the function of driving the connecting element or the reinforcement further into the assembly of the first and second objects. Fig.13 The sonotrode 6 is an annular sonotrode. In most embodiments, the annular sonotrode is designed so that the distal coupling-out end face of the sonotrode covers the lateral position of the protruding section of the second object 2.

[0326] Figure 14a-Figure 14c A specific configuration suitable for use with embodiments of the present invention is described. The configuration involves reversibly fastening another object to a second object at a plurality of fastening locations. Fig.14a A flat plate member 71 is shown as an example of the other object to be movably fastened to the surface of the object (second object) having a flat surface. Application examples of this configuration include fastening a plurality of panels to a vehicle body.

[0327] According to an embodiment of the invention, in contrast, in the method described herein, a fixed connection is provided as the first object 1 (or as a connection of the type defined above). Thus, the first object 1 (as shown in FIG. 14 a) or the connection (e.g. Figure 6 As shown) is provided with a clamping connection structure 13, Fig.14a The peripheral groove is shown in FIG. 1 , and the clamping connection structure and the corresponding structure of another element ( Fig.14a In order to fix the fixed connection to the second object 2, the first object 1 contacts the correspondingly positioned protruding section of the second object 2 when being fastened to the further element (the plate 71 in the described embodiment). Thereafter, the process is carried out as described above. Fig.14b As shown by the double-headed arrow 73 in FIG. 1 , the relative position of the first object and the protruding section does not need to be very precise and can vary within the tolerance given by the dimensions of the first object relative to the dimensions of the protruding section without adversely affecting the fixation. Therefore, the tolerance of the position of the attachment point (perforation and deformation section) relative to the position of the attachment structure (connection part) of the further element 71 is more relaxed than in the prior art methods. However, due to the fact that the first object 1 (or the connection piece) is attached to the further element during the fixation process, the position of the detachable clip connection is accurately fixed. Fig.14c The final assembly is shown with a further element (plate 71 ) removably clipped to the second object 2 .

[0328] Fig.15 An embodiment is shown in which the second object does not have a section protruding into the proximal direction, i.e. towards the first object. Instead, the perforation 20 is punched out (or drilled out or otherwise removed) with its edge located in the plane of the sheet. In contrast to the previously described embodiment, the method will then not work with a first object that is only plate-shaped. Instead, the shape and position of the first object need to be adjusted. More specifically, in the embodiment shown, the first object 1 is an attachment bolt with a gradually narrowing section 101 and a head section 102, wherein the gradually narrowing section is dimensioned so that when inserted into the perforation and moved in the distal direction, it forms a significant and increasing difference with the second object. When the sonotrode 6 presses the first object into the perforation and couples energy into the first object, this will cause the thermoplastic material of the first object to liquefy similarly to the embodiment described above.

[0329] At the same time, the connector 3 (or alternatively the reinforcement) driven into the thermoplastic material will generate a pressure towards the outside on the flowable material. As a result, the edge of the perforation becomes embedded in the thermoplastic material. This process can be carried out until the distally facing face of the head section 102 abuts against the sheet of the second object. Due to the effect of the use of the connector 3 (or reinforcement) forced into the thermoplastic material of the first object 1, the shape of the insertion section 101 does not necessarily have to be gradually narrowing.

[0330] Instead of having a tapered section, the first body may have other shapes, including a stepped or cylindrical shape having a diameter slightly larger than the diameter of the through hole.

[0331] In an embodiment comprising driving a connector or reinforcement into the thermoplastic material to generate outward pressure, the connector / reinforcement has an effect similar to that of the structural anvil described above. However, this embodiment has the advantage of being usable even in situations where the fastening location is not accessible from the distal side.

[0332] exist Fig.16 In a variant of the invention, the metal sheet constituting the second object has a section around the perforation that protrudes away from the first object. In particular, the second object may be formed according to Figure 1a and Figure 1b The embodiment is formed as shown, but turned upside down so that it has a plurality of tongues between which the thermoplastic material can flow. Also in this embodiment, the dimensions of the perforation / deformation section and the dimensions of the protrusion of the first object are adapted to each other on the one hand, in such a way that when the protrusion of the first object is inserted into the perforation, there is a significant resistance to the forward movement (distal movement) of the first object relative to the second object. Also this embodiment can be combined with a connector or reinforcement of the type discussed herein above.

[0333] Fig.17a and Fig.17b An example of a second object is shown in which a plurality of perforations 20 are arranged in a common deformation section protruding away from the proximal side. Fig.15 and Fig.16 A single first object 1 of the type described in is anchored in the indentation formed by this deformation section by the process described above.

[0334] Applications include, for example, fastening plastic parts to metal parts in the automotive and aerospace industries (where the second object is a metal part or a portion thereof).For example, in the automotive industry, lightweight parts of plastic or composite materials often have to be attached to the body of the car.

[0335] Although all described embodiments rely on coupling mechanical energy into the assembly, typically from the side of a first object (from the top in the figures), embodiments are also possible in which mechanical vibration energy is coupled into a second object. Figure 3a In a configuration of , the sonotrode 6 can act from the side which is shown as the lower side in the figures.

[0336] Figure 18a-Figure 24A group of embodiments is shown which comprises fixing a third object to a second object by means of a first object, in particular in the case of access only from one side, the near side (shown as the top side in the figures). In all of these embodiments, the third object 8 is shown as a flat CFK component. However, this group of embodiments also works for the third object, for example, a metal or ceramic material or a plastic (which is, for example, non-liquefiable in the sense that it does not liquefy at the temperatures reached in the process) or any other suitable material used in the construction. Likewise, the second object is shown as a metal sheet. However, the method also works for other materials that can form an edge around the perforation. The method is particularly advantageous for constructions in which the second and third objects have different coefficients of thermal expansion; however, this is not a requirement for the use of the method.

[0337] Fig.18a The first object 1 in the embodiment is used as a connector for fixing the third object 8 to the second object 2. The first object has a thermoplastic material portion 15 and a reinforcing portion 16, for example metal, as a non-liquefiable core. The core 16 forms the head 91 of the first object and extends inside the shaft portion. In the illustrated configuration, the core 91 is covered by the thermoplastic material portion 15 along the entire shaft, but it is possible to provide the thermoplastic material portion only as a partial covering layer, for example leaving the distal end of the core without any covering layer or leaving certain sections around the periphery without any covering layer.

[0338] The third object has a third object opening 81 which is a through opening. The shape of the second object 2 is substantially the same as that of the third object 81. Fig.16 The diameter of the perforation (similar to Figure 1b More specifically, the cross section of the shaft portion 92 allows it to fit through the opening but not through the through hole.

[0339] After the first object has been inserted through the opening and pressed by the sonotrode 6 in the distal direction against the second object 2, the thermoplastic material becomes flowable by simultaneously coupling mechanical vibration energy into the first object 1 by the sonotrode 6. This process continues until the forward movement (distal movement) of the first object is stopped by the head 91. Next, the vibration energy input is stopped and the sonotrode is removed. Fig.18b The result is shown in Figure 14 where the material portion 14 has flowed to the far side of the second object to form a blind rivet-like foot. Fig.18bIn the configuration of the first object after this step forms the rivet, the second and third objects are clamped between this foot and the head 91. If the glass transition temperature of the thermoplastic material used is a value between room temperature and about 160°C, the rivet connection has the advantages discussed above with respect to compensating for different thermal expansion coefficients in the electrodeposition step such as painting / varnishing. For example, the glass transition temperature of acrylonitrile is about 130°C-140°C.

[0340] Fig.19 A variation of the first object is shown in which the core 16 has a distal punch edge 93. This distal punch edge can be used to punch out perforations during the process.

[0341] As another variation, Fig. 20 A first object is shown having a (metal) core forming a distal piercing tip 94. This piercing tip can be used to form a second object by piercing a metal sheet forming the second object including a deformation around the mouth (e.g. Fig.18a perforations as shown).

[0342] In embodiments involving piercing, a waist 96 may optionally be present so that after the piercing step the sheets no longer clamp the core and relative vibration becomes possible.

[0343] exist Fig.19 and Fig. 20 In both embodiments, the process is basically as described in reference to the punching / piercing step. Fig.18a and Fig.18b The description continues.

[0344] Fig.21 Another variant is shown, the first object is suitable for a group of embodiments including fixing a third object to a second object via the first object, the object having no core or other reinforcement but being made of thermoplastic material. Also in this embodiment, the head 91 may be present in addition to the shaft 92.

[0345] Fig. 22 The embodiments show further features which may be implemented in combination or individually or independently of each other.

[0346] The core 16 comprises structures 95 which are suitable for forming a form-fitting connection (here: relative movement with respect to the axial direction) or for otherwise strengthening the connection between the core 16 and the thermoplastic material part 15 .

[0347] - The core has a smaller axial extension (extending along the proximal-distal axis) so that it does not necessarily extend through the perforation. More generally, no specific extension / dimension of the core (if any) is required, but in configurations where significant shear forces are expected between the second and third bodies, it may be advantageous if this core extends through both the opening and the perforation.

[0348] exist Fig.23 In a variation of the second object 2, there is no bending around the perforation to protrude away from the third object (with Fig.18a The invention is generally flat.

[0349] However, anvils are useful in many embodiments of the present invention, including those described herein where no reference is made to an anvil similar to Fig.23 An anvil of the embodiment of the embodiment of the present invention, however, an anvil with a corresponding surface structure as described above may be particularly advantageous for guiding the material to flow along the edge 21 towards the distal side of the second object part.

[0350] exist Fig.24 In a variation of Fig.17a and Fig.17b Describes a shape having multiple smaller protrusions instead of one larger protrusion.

[0351] Fig.25a An example of an arrangement is shown in which a third object 4 is fixed to a second object 2 by means of a first object 1 , wherein both the second object and the third object generally have a flat sheet with an edge.

[0352] exist Fig.25a In the embodiment of the present invention, the second object has a second object perforation 20, and the second object edge 21 extends along the second object perforation 20, and the third object 4 has a third object perforation 40, and the third object edge 41 extends along the third object perforation 40. The corresponding objects 2, 4 are deformed along the perforations so that the sheet protrudes away from the corresponding sheet plane.

[0353] The objects 1 , 2 , 4 are arranged such that the first object is sandwiched between the second and third objects and the sheets of the second and third objects protrude toward the first object 1 , ie toward the near side of the second object 2 and the far side of the third object 4 .

[0354] In the process, opposing pressures are exerted on the second and third objects, whereby the first object is clamped between the second and third objects. At the same time, mechanical vibrations can be coupled into the assembly. Thereby, for example, the vibrating sonotrode 6 presses the third object 4 against the first object 1, whereby the first object 1 is pressed against the edge 21 of the second object, which in turn is placed against the non-vibrating support 7, which exerts an opposing pressure as a normal force.

[0355] exist Fig.25a In an embodiment, the vibration is coupled into the arrangement via a third object. When the vibration is initiated, the vibration of the third object may cause the first object to also vibrate before the material portion becomes flowable. If the parameters of the objects are appropriately selected (angle α, sharpness of the edge, length of the edge, material stiffness, etc.), the heating process at the interface towards the edge 21 of the second object starts before or almost simultaneously with the start of the heating process at the interface towards the edge 41 of the third object. In particular, the second object 21 may be formed to be more inclined to absorb energy at the interface (e.g. due to being more inclined) than at the edge 41 of the third object. Thus, even if the vibration can only be coupled into the third object, it is possible to achieve anchoring of both the second object and the third object into the first object.

[0356] Fig.25b The situation is schematically shown after the energy input has ceased, with the flow portion 14 having a sub-portion which has flowed along the edges of the second and third objects.

[0357] according to Fig.26 In the variant shown, both the second object 2 and the third object 4 are subjected to mechanical vibrations, wherein the assembly of the second object 2, the first object 1 and the third object 4 is clamped between two vibrating sonotrodes 6.1, 6.2 exerting opposite pressures. This embodiment is less sensitive to the edge properties of the second and third objects.

[0358] Figure 27-Figure 29 25a for an asymmetric arrangement where energy is input from only one side. Parameters that can be varied include the slope ( Fig. 27 Angle α), edge length ( Fig.28 ), edge sharpness ( Fig.29 )wait.

[0359] Fig.30 Another example of an embodiment of the second object and the third object is shown, wherein the second object and the third object contact the first object from opposite sides. Fig.25a and Fig.26 Unlike the embodiment of the present invention, the first object includes at least one protrusion (two ridges 117, 118 in the embodiment shown) protruding from the corresponding proximal / distal side 11, 12, and the edge 21, 41 of the second object / third object is pressed against the proximal / distal side 11, 12. The ridges 117, 118 (or other (multiple) protrusions) are designed so that their height is greater than or equal to or only slightly less than the height h of the corresponding deformed section along the edge (see Figure 1b). When the sonotrodes 6.1, 6.2 are pressed against the third and second objects 4, 2, they are thus in direct contact with the sonotrodes, so that in the process mechanical vibration energy is applied to their ends 113, 114, whereby the material located at these ends becomes flowable and Fig.30 As indicated by the arrows in the figure, the space can be filled along the edge. In addition or as an alternative to the protrusions showing the height, protrusions can be provided for the respective sonotrode 6.1, 6.2.

[0360] The flowable material that has been produced at the interface between the protrusion and the sonotrode may help to secure the second object / third object to the first object, for example by helping to achieve a form-fit connection.

[0361] Fig.30 The concept can be applied to arrangements with only one sonotrode (with Fig.25a In one embodiment, the first object is provided with a protrusion only on one side facing the ultrasonic welding electrode, or on both sides, the side facing away from the ultrasonic welding electrode has an energy conducting structure or is otherwise designed to absorb energy vibration energy more easily than the side facing the ultrasonic welding electrode.

[0362] Fig.30 The embodiment is a conceptual example of a portion (especially a protrusion) of the first object that is directly in contact with the ultrasonic welding electrode when the ultrasonic welding electrode acts on the second object 2 (or the third object), thereby forming a sub-portion of the flow portion at the interface between the ultrasonic welding electrode 6 and the first object 1 to fill the space.

[0363] This concept can also be used for constructions that are not based on the principle of providing a second object and a third object, both of which have edges that are embedded in the material of the first object during the process. In addition, it can also be applied to embodiments in which only the first object is fixed to the second object (and the first object can optionally be configured to serve as an anchor for any other object). This Fig.31 In this configuration, the ultrasonic welding electrode is welded from the side ( Fig.31 The bottom side of the second object 2 and the first object 1 are pressed against the non-vibrating support ( Fig.31 not shown).

[0364] In a similar Fig.30 and Fig.31 In an embodiment in which an end of the first object is rendered flowable, the end may optionally have a shape that facilitates such liquefaction. Fig.31a A corresponding example is schematically shown, where there is a reduction edge ( Fig.31aThe tube 17 below the tube 17 forms the end. This shape will form an energy guide and at the point where the tube contacts the ultrasonic welding electrode (or in another configuration, if the ultrasonic welding electrode is from the Fig.31a The upper side effect shown, the liquefaction between the pipe and the non-vibrating support or a part of the second object or other non-vibrating object) will be greater than Fig.30 and Fig.31 The shape shown starts more quickly.

[0365] Fig.32 An embodiment of a subset of the second and third objects 2, 4 is shown in which the second and third objects 2, 4 are brought into contact with the first object 1 from the same side. Fig.32 In the embodiment, the second object 2 and the third object 4 both have perforations 20, 40 around which the sheet material is deformed to protrude toward the first object 1. In order to fix the second and third objects together by the first object, the second and third objects are positioned one above the other, wherein the perforations are arranged approximately coaxially.

[0366] exist Fig.32 In the construction of Figure 3a The vibration may be applied to the first object from the side facing away from the first object and the second object to embed the edges 21, 41 into the thermoplastic material, while the third object is adjacent against the non-vibrating support. Mechanical vibration may also be applied from the side or both sides of the third object.

[0367] exist Fig.33 In a variation of the embodiment of the invention, the second object and the third object are not placed one above the other but are placed adjacent to each other by means of the first object. In this embodiment, the second object is not perforated. Instead, the peripheral edge of the sheet is used for the process. The peripheral edge 41 of the third object is arranged adjacent to the peripheral edge 21 of the second object and is passed through the process (similar to FIG. 3a / Figure 3b ) are embedded in the thermoplastic material to fix the first object, the second object and the third object to each other.

[0368] In arrangements where the edge is not an edge along a perforation but is in particular a peripheral edge, it is advantageous if the peripheral portion along which the edge extends is provided with a curved structure or a structure having corners so that the edge does not extend in a straight line, in particular if in-plane forces (shear forces) are expected to act on the connection between the objects. Fig.34a The peripheral parts of the second body 2 and the third body 4 adjacent to each other are shown very schematically, wherein the peripheral parts are provided with a curvature which is here partially corrugated.Thereby, in-plane forces in two in-plane directions x and y can be absorbed by the connection.

[0369] like Fig.34b As shown, if the third object 4 is similar to Fig.33If the third object is arranged next to the second object (solid line), then the non-linear structure of this peripheral part is not only advantageous. Instead, the dotted line shows other possible arrangements of the third object that will be fixed to the second object by this process.

[0370] Reference Figure 3a , Fig.33 et al., describe the principle of coupling mechanical vibration energy into a first object in order to transfer the vibration energy to the interface with a second object (and, if applicable, a third object). The parameters are usually selected so that the thermoplastic material does not appreciably liquefy when in contact with the sonotrode. On the contrary, Fig.30 and Fig.31 The described embodiments describe embodiments where targeted liquefaction at the sonotrode-first object-interface is used to liquefy other portions of the thermoplastic material to fill the structure.

[0371] Fig.35a and Fig.35b Another example of this is shown schematically. Fig.34a , the sonotrode is shown with a peripheral protrusion 64 having an oblique shoulder configured to make the edge portion of the first object flowable and deformable and to laterally limit the flow of the flowable material. This will result in a well-defined smooth edge area of ​​the assembly comprising the first object and the second object (and, if applicable, the third object).

[0372] exist Fig.35a and Fig.35b , which can be realized independently of the "liquefaction at the sonotrode-first object-interface" and / or defined features. However, this optional feature in combination with a well-defined shape resulting from a protrusion or other dedicated sonotrode shape can have particular advantages in certain embodiments. This other optional feature is that the second object 2 has a deformed edge protruding toward the first object, which extends along the entire periphery of the second object and is completely embedded in the material of the first object ( Fig.35b ), therefore, the surface of the second object (towards the near side, Fig.35a and Fig.35b above) and the surface of the first object (at Fig.35a and Fig.35b If, for example, an element (not shown) is attached to a second object at the surface facing the first object, this approach forms an enclosure that completely seals the element and protects it from moisture and other possible environmental influences.

[0373] The feature of embedding the entire periphery of the second object within the thermoplastic material of the first object can be combined with the fixing of the third object 4 (such as Fig.35a and Fig.35bThe invention can be done in combination with or without a third object (as shown), ie in a configuration without a third object having a sheet with an edge to be embedded in the thermoplastic material.

[0374] Fig.36 Another embodiment of a first object 1 (or a plurality of first objects) to be mechanically fixed to a second object is shown. This other embodiment is an example of an embodiment in which the thermoplastic material becomes flowable not only when in contact with the edge but also at the contact surface with other parts of the second object. More specifically, in the embodiment shown, the second object has a first part 24 and a second part 25, the first part 24 being composed, for example, of a first substantially flat metal sheet, the second part 25 comprising an edge and here being formed by a second metal sheet attached to the first metal sheet, and forming at least one protuberance with a perforation at the top. The first object has a head 102 and a shaft 103, for which the shaft is introduced through the perforation until the distal end of the shaft 103 abuts the first part 24 of the second object and / or the shoulder formed by the head 102 towards the distal side abuts the edge of the second part of the second object. When mechanical vibration energy is applied, the rim is embedded in the thermoplastic material and the distal end of the shaft portion becomes deformable and is pressed outwardly to expand the shaft portion laterally, so that the first object is additionally anchored by a blind rivet effect. Thus, the shaft portion is optionally sized so that most of the volume defined below the ridge (between the first and second parts of the second object) is filled with thermoplastic material.

[0375] In such Fig.36 The first part 24 of the second object in the embodiment of the present invention can be used as an anvil of the type described above by the described method. Optionally, it can be deformed as described above so that the anvil forms a flow guiding structure. According to a further alternative, it can be replaced by a separate object having the function of an anvil.

[0376] exist Fig.36 , the right side shows the first object 1 after the process, the flow portion 14 comprising a portion towards the distal end and located at the interface with the rim.

[0377] Fig.37 shows an alternative for use similar to Fig.36 The optional first object of the embodiment of the invention is collapsible and has a proximal portion 105 that forms a default collapsed position.

[0378] exist Fig.30 , Fig.31 , Fig.36 , Fig.37 In a variation of the embodiment of the present invention, the shape of the distal end of the first object may be similar to Fig.31aThe design shown is designed to cooperate with the components (second object part, sonotrode, anvil) to act in a flow-guiding manner.

[0379] Fig.38 1 shows a processing diagram for an embodiment of the method described herein. Curve 121 shows the pressing force acting between the first object and the second object, and curve 122 is the vibration energy power, both as a function of time. Fig.38 As shown, in an optional first phase 125 (pre-pressing), which may be shorter or even omitted, the first object is pressed against the second object without any vibration effect. This first phase may be advantageous, for example, to ensure that when the vibration starts, the pressing force and thus the coupling force between the sonotrode and the first object (or, if applicable, the second object or other object of the assembly) allows an effective coupling between the sonotrode and the object, for example to prevent melting at the interface between the sonotrode and the first object. In the second phase 126, while the pressing force is maintained, the vibration is coupled into the assembly. According to this configuration, instead of a constant value as shown, the pressing force may follow a specific trajectory. In the third phase 127 (post-pressing phase), the vibration is turned off, but the pressing force is maintained for a longer time until the flow portion has resolidified enough to prevent any undesirable loosening or rebound effects, etc. from occurring. In this third phase 127, the second object can be pressed further into the first object along the edge. Therefore, optionally (dashed lines), the pressing force can be even further increased during the third phase.

[0380] Fig.39 The configuration shown is similar to that described above (e.g. Figure 3a ) but with an additional element: an elastic seal 131 is placed relative to the first and second objects before the step of applying the pressing force and mechanical vibration. The seal is placed in a position where the pressing force and the relative movement of the first and second objects caused by it after the start of liquefaction (making it flowable) compress the seal 131, here between the first and second objects. An additional sealing effect can thus be obtained. In the illustrated configuration, the seal 131 is a sealing ring surrounding the perforation 20 in the second object, whereby the connection between the first and second objects is on the side facing the first object ( Fig.39 The upper side of the housing is completely sealed.

[0381] Also in the embodiment having a seal compressed between a first object and a second object, the processing diagram is similar to that in Fig.38 , but because the seal will cause a rebound effect if the flow portion is not sufficiently stiffened, the third stage 127 (post-pressure stage) is particularly long.

[0382] exist Fig.41In another embodiment example shown, the seal 131 is placed relative to the first object and the second object before the opening pressure and vibration. Figure 8 In the embodiment of the embodiment of the present invention, the seal 131 is compressed between the connecting member 3 and the first object 1 and is therefore located on the side of the first object facing away from the second object. Fig.41 In FIG. 1 , the seal is shown forming a sealing ring. Fig.41 In the embodiment of the present invention, it is also possible to place an additional seal in the Fig.39 Position shown.

[0383] In a similar Fig.39 and Fig.41 In the embodiment of the present invention, a corresponding amount of adhesive may be used to replace the elastic seal 131 and distributed to form a closed ring such as the seal 131 shown.

[0384] Fig.42 The third object 8 to be fixed to the first and second objects 1, 2 (or to the other of the first and second objects by means of one of the first and second objects) can be connected to the first object by an additional form-fit connection between the first and third objects. To this end, the third object 8 comprises at least one direction ( Fig.42 The axial direction in the middle has an undercut structure. Fig.42 In the embodiment of the invention, the structure is arranged on a protrusion 45 of a third object 8, which is pressed into the material of the first object in this step when mechanical vibration energy is coupled into the system. The objects are placed relative to each other so that the portion of the second object around the perforation is located between the first object and the third object and the protrusion 45, which passes through the perforation of the second object and thereby contacts the first object.

[0385] For example, reference Figure 5a / Figure 5b or reference Figure 6 or Figure 7 or Figure 8 , Fig.42 The protrusion 45 of the embodiment is similar to the corresponding structure of the connecting member described above.

[0386] Independent of the shape of the third object including the protrusion with the form-fitting structure Fig.42 Another feature of the embodiment is that the third object 8 is different from FIG. 5- Figure 8The vibration energy application step resulting in embedding the edge of the second object and the part of the third object (here: the protrusion) will thereby cause the thermoplastic material to flow back toward the second object and the third object side, so that the space between the protrusion 54 and the sheet will be at least partially filled.

[0387] Likewise in Fig.42 In the configuration shown, this process will result in the second object 2 being sandwiched between the first and third objects.

[0388] Fig.43 Shows Fig.42 A variant of an embodiment of the invention in which the form-fit connection between the first object and the third object comprises the penetration of the material of the third object 8 into the undercut structure 141 of the first object 1. Thus, the third object may comprise a thermoplastic material which becomes flowable under the influence of vibration energy and pressing force, at least in the region of the protrusion 45. In this embodiment, the thermoplastic material of the third object may have the same or different composition than the thermoplastic material of the first object.

[0389] Depending on the material pairing of the thermoplastic materials of the first and third body, a weld can also be produced between these bodies in this embodiment with or without an undercut structure present in one of the bodies.

[0390] In an embodiment, the method comprises providing the second object with a plurality of attachment sites, each attachment site comprising an edge of the sheet, and for each attachment site coupling mechanical vibration energy into the assembly until a flowing portion of the thermoplastic material becomes flowable due to frictional heat generated between the edge and the thermoplastic material and flows around the edge thereby at least partially embedding the edge into the thermoplastic material. This may be done simultaneously for all attachment sites or for a subset of attachment sites, or may be done sequentially for the attachment sites. Each attachment site may, for example, comprise a perforation 20 of the type described above, with an edge extending along the perforation.

[0391] Fig.44 Very schematically, a second object 2 is shown with a plurality of attachment sites 200. In general, these attachment sites can be arranged regularly or irregularly, distributed in two dimensions or one dimension (along a line). In particular, a two-dimensional arrangement of the attachment sites will bring stability with respect to tilting forces in all directions, even if, for example due to the limited thickness of the first object, the attachment sites themselves are relatively small and / or if the height h (see Figure 1b ) is relatively small. This two-dimensional arrangement can therefore form a mechanically stable connection even with a very thin first object.

[0392] The connection described herein above is characterized as a connection between a first object and a second object (in a manner similar to that including a third object). Fig.34a / Fig.34b In an embodiment) relative forces in all in-plane directions may be absorbed, wherein the edge(s) include portions extending in different in-plane directions and protruding into opposite directions.

[0393] The fact that the rim comprises two parts that at least partially project into opposite directions (the direction in which one of the parts projects has a part of the axis along the direction in which the other of the parts projects, the part having the reverse marking) and that the rim extends into different directions may be advantageous in many cases as it may provide a form of locking to all in-plane directions. In the embodiments described above, the parts are formed around a single perforation.

[0394] Fig.45a and Fig.45b ( Fig.45b Shown along Fig.45a BB) shows an alternative, in which the tongues 28 forming the deformation sections lock the first object only in one in-plane direction per perforation 20. However, the tongues 28 belonging to different perforations protrude in different directions, including directions with components in opposite directions. Together, they lock the first object in all in-plane directions.

[0395] Fig.46 The mechanical connection of the invention is suitable for tolerance compensation in many aspects: the attachment point at the first object does not need to be predefined and can be changed, the only condition is that the edge embeds the thermoplastic material - so there must be thermoplastic material at the location of the edge 21 and where the material will be embedded.

[0396] - Thus, the lateral position (xy position in the coordinate system shown) of the edge 21 (or more generally: of the attachment site) can therefore vary within a corresponding lateral dimension of the first object 1 or its thermoplastic attachment zone 112. Fig.46 Medium, m x represents the possible mismatch in relative, lateral x-position between the two possible arrangements.

[0397] - The relative axial position (z position) can also be varied. In order to have sufficient strength to resist axial tension, the embedded part P in the z-protrusion z The size must have some minimum value P z，min In practice, depending on the application, a minimum z-protrusion value of the embedded part of between 0.2 mm and 1 mm is sufficient (of course larger values ​​are not excluded). As long as this minimum dimension is reached, the edge is pressed into the first object (tz ) need not be defined in advance. Thus, the relative z-position of the first and second objects relative to each other can be within limit values, which are only given by geometric constraints (for example if the surfaces abut each other) and specified minimum dimensions. Fig.46 Medium, m z represents the possible mismatch in relative z-position between the two possible arrangements.

[0398] 116 refers to when the sheet is pressed into Fig.46 The first object in the flow is the area affected by the material flow.

[0399] Taking into account the depth in the z direction and possible z-tolerances, the angle α (see Figure 1b ; Figure 46 shows that the angle β = 90°-α) may be a useful parameter. Fig.47 It is shown that for different values ​​of mechanical stress σ experienced by the connection, the minimum depth t required is generally larger for the angle β. z，min The bigger.

[0400] Due to the illustrated possibility of tolerating z-mismatches, angular mismatches can also be compensated by the connection according to the invention. Fig.48 It is shown very schematically in FIG. 1 , where there is an angular mismatch γ between a sheet plane of the second object 2 and a corresponding plane of the first object.

[0401] Fig.48 The principle is also shown that the axial direction of the sonotrode 6 pressing the first and second objects against one another is not perpendicular to the sheet plane (irrespective of tolerance compensation).

[0402] In many embodiments, the first object to be secured to the second object will not be comprised of a thermoplastic material, but will have portions other than thermoplastic portions. Fig.49 As shown, the first object 1 has a functional area 111 in addition to at least one attachment area 112. The lateral dimensions and the z-direction dimensions of the one or more attachment areas 112 can be designed according to the required tolerances.

[0403] In an embodiment, the first object comprises at least one functional area 111 not suitable for attachment to an attachment site of the second object and a plurality of attachment areas 112 comprising a thermoplastic material.

[0404] In one set of embodiments with functional areas and attachment areas, the first object comprises two thermoplastic parts, the first thermoplastic part comprising a thermoplastic material for embedding the edge, and the second thermoplastic part comprising a different thermoplastic material, the different thermoplastic materials having different properties.

[0405] Fig.72A corresponding example is shown. The first thermoplastic material component 356 defines and / or holds the functional element. Fig.72 In FIG. 3 , an internal thread 358 is schematically shown. The second thermoplastic material component / components are used to attach the first object 1 to the second object 2.

[0406] Thermoplastic components have different material properties.

[0407] The modulus of elasticity E of the first component is greater, for example much greater, than the corresponding modulus of the second component.

[0408] The (elastic) extensibility of the second part(s) 357 is much greater than the extensibility of the first part 356 .

[0409] Thereby, different thermal expansion behaviors between the first object and the second object can be compensated.

[0410] In particular, the first object including two thermoplastic materials according to the present embodiment can be manufactured by two-color injection molding.

[0411] In an embodiment, the present invention relates to a method for attaching a first object and a second object to each other using a method as described and claimed herein, wherein the second object has at least one attachment location, in particular a plurality of attachment locations, consisting of a defined edge and a (e.g. deformed) portion protruding toward the first object, and wherein a first tolerance for positioning the attachment location on the second object is greater than a second tolerance corresponding to a tolerance for ultimately positioning the first object relative to the second object.

[0412] In other words, the present invention is particularly applicable to situations where relatively precise relative positioning of objects relative to each other may be required (including the need to position one of the objects relative to a third object to which the other object is fixed), but precise positioning of the attachment points is not required. As a result, a significant increase in efficiency is achieved, since precise relative positioning of the attachment points is a challenge in complex devices, and the present invention does not require such precise positioning. However, the position of one component (e.g. a first object) relative to a complex device including another component can be very accurately defined, including the possibility of manually adjusting the position before applying vibration energy.

[0413] For example, the present invention may include manufacturing multiple components, each component including a first object fixed to a second object, wherein the second object includes at least one attachment site, and the standard deviation of the positioning of the attachment sites between different components is greater than the standard deviation of the positioning of the objects relative to each other (and / or the positioning of one of the objects relative to a third object to which the other objects are fixed).

[0414] Fig.50a and Fig.50bA possible way of accurately guiding the positioning of a first object 1 relative to a second object before applying mechanical vibration energy is shown. A guiding tool 162 having at least one guiding protrusion 163 supports the first object 1 by means of the guiding protrusion 163 engaging in a lateral guiding recess 161 of the first object, wherein the guiding protrusion has a more pronounced curvature than the guiding recess 161, so that the guiding tool can hold the first object and accurately define its lateral position, the description of which uses the xy position in a coordinate system, so that when the sonotrode is used to act on the first object 1, free vibration along the z-axis is still possible. Fig.50b It is shown that, for example, the first object can have three lateral guide recesses, into which the guide projections of the guide tool can engage in a finger-like manner.

[0415] For example Fig.11 and Fig.12 As shown, another possibility for guiding the positioning of a first object relative to a second object for attachment is to use a sonotrode.

[0416] The various embodiments of the present invention have numerous applications in various fields of mechanical engineering and manufacturing. A first example is in Fig.51 1 is shown very schematically in FIG. The first object 1 is a holder (with a holding structure 151) for an object 152 to be positioned to a frame, to which the second object 2 belongs. The frame may have a complex construction, with the attachment site 200 being difficult to position precisely, for example.

[0417] In an embodiment relating to automotive engineering, the frame may be, for example, a vehicle body or a part thereof, and the object may be a device having a position visible to the user, such as a technical, functional or optical decorative element located in the interior of the vehicle. The mechanic in charge of the assembly can position the holder 1 with, for example, the integrated object 152 in a precise manner relative to visible markings and / or reference points, thereby creating a pleasing impression.

[0418] Attachment to the different attachment sites 200 may be done simultaneously or sequentially.

[0419] Fig.51 A special feature of the embodiment of (which is also an option for embodiments in which the first object has a different purpose than the frame) is that the first object has an attachment flange 156 to which the sonotrode 6 can be placed attached, the attachment flange defining an attachment area surrounding the functional area.

[0420] The attachment flange forms a peripheral, laterally protruding portion of the first body 1. It can consist of a thermoplastic material; at least on the distal side it comprises a thermoplastic material. It defines a coupling-in surface 158 facing proximally parallel to the distal surface of the first body, which is in contact with the edge of the second body 2. Thus, even if the first body has a complex shape ( Fig.51 A planar distal surface is shown for illustrative purposes, but different surface shapes are possible), and less complex shapes are also possible at the attachment site(s).

[0421] The attachment flange may, but need not, extend around the entire periphery of the first object.

[0422] For attachment, a single sonotrode extending around the periphery of the first object may be used if the dimensions permit this. Alternatively, particularly if the energy input of this single sonotrode approach is too high, multiple sonotrodes may be used acting simultaneously on the first object at different attachment locations.

[0423] According to a further option, the object can be acted on sequentially at different attachment sites with one sonotrode or with a plurality of sonotrodes. If this is the case, the vibration coupling between the respective attachment site to which the sonotrode is pressed and the rest of the first object can become a problem. In particular, it is necessary that the process works properly, i.e. not too much vibration energy is conducted away from the attachment site and coupled into the rest of the first object. The mechanical connection between the component with the attachment site and the rest of the object can also become a problem, since the anchoring process involves moving the first object distally relative to the second object (or vice versa) at the attachment site that couples energy into the first object (or second object), whereas this movement is not possible at the other attachment sites.

[0424] Depending on the configuration, the use of an attachment flange that is peripheral and constitutes a relatively flexible structure is sufficient to meet these requirements. In an alternative set of embodiments, the first body includes an elastic joint 350 located between the attachment flange 156 and the first body. This is for example in Fig.69 and Fig.70 In Fig.69 In an embodiment of the present invention, the elastic joint comprises a neck that vibrationally decouples the attachment flange from the first object. Fig.70 A spring element which more generally constitutes an elastic joint is shown in FIG.

[0425] Fig.71Another optional feature of an embodiment is shown, particularly but not exclusively with an attachment flange. The first object may include at least one, for example a plurality of, dedicated, possibly marked, proximally oriented coupling surface portions 159, which are positioned corresponding to the attachment site defined by the second object 2 (e.g., located at a position corresponding to a perforation of the second object, with an edge extending along the perforation of the second object). This coupling surface portion is parallel to the distal surface portion that contacts the edge of the second object.

[0426] Fig.119 An embodiment is shown in which the attachment structure is not an annular flange but rather includes a plurality of attachment tongues 650 extending outwardly from a body 660. Fig.119 In the embodiment of FIG. 1 , an optional resilient joint 350 is shown between the body and the attachment tongue. Fig.119 An embodiment with a tongue instead of a plurality of discrete flanges surrounding the main body is also schematically shown in , particularly but not exclusively applicable to the case where the second object is not flat but has a more 3D shape.

[0427] exist Fig.119 Another independent feature is also shown in FIG. The ultrasonic welding electrode 6 includes a marking portion. Thus, a mark 671 is generated in the process, such as Fig.120 A top view of one of the attachment tongues after this step is schematically shown. This marking 671 is advantageous in the production phase after the fixing step, for example for enabling an operator to see where the second object located underneath has a perforation, for example so that he can drive an element (screw, pin, etc.) through the assembly if necessary.

[0428] Fig.52 Another application is shown, namely that the first object 1 is a base for positioning an item 172 by friction and / or snap-fit ​​engagement. For snap-fit ​​engagement, the item 172 comprises lateral protrusions 173 to engage into snap-fit ​​recesses 171 of the first object.

[0429] exist Fig.53 A further application is shown very schematically. Here the deformation section of the second object 2 has sufficient dimensions to allow the first object 1 to be attached while the non-embedded part of the deformation section still has a considerable extension so that the first object does not abut against the sheet plane. Depending on the extension of the edge, if the second object is sufficiently elastically deformable, this leaves the possibility of a tilting movement of the first object relative to the second object, so that the first object and the second object vibrate apart relative to each other.

[0430] Fig.54In the embodiment shown the second object 2 does not have a metal sheet in the strict sense, the edge of which forms the edge. Instead, the second object is a die cast metal object, e.g. processed without any deformation step. The edge is a ridge 29 formed by the die casting process.

[0431] - Thus, arbitrary edge shapes become possible. This includes the possibility to have multiple ridges 29 and thus multiple edges adjacent to each other.

[0432] -Similarly, however, in many similar Fig.54 In the embodiment of the second object, the second object will have an extended flat, plate-like or sheet-like portion, which is not required. Instead, because the edge is formed by mold casting, the object can have any basic shape and still include an edge. For example, in Fig.54 In the embodiment of FIG. 2 , the sheet-like portion is formed by relatively small ridge-like protrusions 29 terminating at the edge.

[0433] The principles of an embodiment of the present invention including the concept of adjusting the z-position of the adjustment component relative to the anchoring component are described below. Generally, the z-direction is assumed in the described and illustrated embodiments to be the direction perpendicular to the plane defined by the second object 2 around the attachment site (sheet plane), and it may correspond to the direction (axis) in which the vibrating tool is pressed to fix the first object to the second object. The principles described below are to be understood as general principles for adjusting the z-position and are not meant to be limited to the specific geometric dimensions and configurations shown. In all figures illustrating the concept, the second object is shown having a Figure 1a-Figure 2b However, this concept also applies to embodiments with other types of attachment points for implementing the method according to the invention.

[0434] Fig.55 A first example of an embodiment comprising a method of adjusting the z-position of an adjusting member 201 relative to an anchoring member, the anchoring member consisting of a first object 1 is shown. This embodiment belongs to the group of embodiments in which the adjusting member 201 comprises a thermoplastic material and can be welded to the anchoring member.

[0435] As for other embodiments described herein, the adjustment component may selectively include functional elements, such as connecting parts, flanges, integrated functional carriers (such as electronic / functional or other functional devices), etc.

[0436] To implement the method, for example, in a first stage, the first object 1 is fixed to the second object 2 using a sonotrode in the manner described above. Here, a step of pressing the first object distally while coupling energy into the assembly can be implemented until the distal side 12 comes into contact with a flat portion of the second object, whereupon the mechanical resistance to further distal movement of the first object 1 increases significantly. As a result, the z-position of the first object relative to the second object is well defined.

[0437] In the second phase, the position of the adjustment component 201 relative to the first object 1 is adjusted and fixed. Thus, the other sonotrode 206 drives the adjustment component distally, overcoming the mechanical resistance, while the vibrations are coupled into the sonotrode and from the sonotrode into the assembly. Due to the mechanical resistance, friction heat is generated at the interface between the first object 1 and the adjustment component 201, so that the material of both components becomes flowable. As a result, firstly, a further distal movement of the adjustment component becomes possible and, secondly, a weld is produced between the first object 1 and the adjustment component 201 after resolidification. The drive movement is carried out until the desired z-position is reached, in particular to compensate for tolerance variations. The indication Δz represents a possible variation of the relative z-position.

[0438] The sonotrode 6 and the further sonotrode 206 are shown as different devices. In alternative configurations, this is not necessary. For example, if the sonotrode is not symmetrical about the axis, then this sonotrode can also be used for the drive and fixing steps of the adjustment component after adjusting its orientation (for example, twisting by 90°).

[0439] According to another alternative, the (first) sonotrode 6 and the further sonotrode 206 can be active simultaneously or partially simultaneously (in the latter case, for example, the further sonotrode starts to act before the (first) sonotrode 6 has stopped). The relative position of the first sonotrode 6 and the further sonotrode 206 defines the adjustment of the z position.

[0440] In the illustrated embodiment, the mechanical resistance required to prevent forward (distal) movement of the adjustment member is obtained by the following geometric features:

[0441] - the first body 1 (anchoring member) has a stepped or proximally tapering outer surface;

[0442] The adjusting member has a tubular distal portion placed over the tapered portion of the anchoring member.

[0443] Fig.56 Examples and Fig.55The embodiment of the invention is based on a similar principle. However, unlike the latter, the adjustment of the z-position of the adjustment component 201 relative to the anchoring component (first object 1) is not performed by applying pressure to drive the other sonotrode to move an adjustable distance, but by moving the adjustment component 201 relative to the anchoring component before the energy input for fixing the adjustment component, for example before positioning the other sonotrode 206. In the embodiment shown, the anchoring part has an external thread 212 that cooperates with the internal thread of the adjustment component 201, so that the position can be adjusted by rotating the adjustment component 201 relative to the anchoring component fixed to the second object 2. Thereafter, the other sonotrode 206 can input energy to weld the adjustment component relative to the anchoring component (first object 1), thereby fixing the adjustment component to the anchoring component.

[0444] Instead of having an external thread, the first body 1 can also have an internal thread that cooperates with an external thread of the adjustment component. Also other means of temporarily locking the z position for a subsequent fixing step are possible, such as a snap-fit ​​with different fixing depths (discrete adjustment) or the like.

[0445] Fig.57a and Fig.57b An embodiment of an anchoring component (first object 1) and a corresponding adjustment component 201 are shown, respectively. The adjustment component 201 has an annular section shaped to be placed opposite the anchoring component so that it is guided by the central proximal part of the anchoring component. The adjustment component 201 is thus rotatable relative to the anchoring component. Here, the ramp section 262 of the adjustment component is located above the ramp section 261 of the anchoring component, so that similar to a threaded connection, the rotation of the adjustment component relative to the anchoring component causes a displacement of the relative z position. At least one of the ramp sections 261, 262 can be formed into a wave shape (as schematically shown), so that in the subsequent fixing step, the ultrasonic welding electrode presses the components against each other and the components are not displaced relative to each other.

[0446] Fig.58a An anchoring component and an adjustment component 201 are shown as a first object 1, wherein the component (in Fig.58a One of the adjusting components (in the middle) has a pattern of protrusions 221 facing the other component. For adjustment and fixing, the adjusting component 201 is pressed toward the anchoring component by the ultrasonic welding electrode when energy is applied, so that the adjusting component is fused to the anchoring component.

[0447] The projections serve here both as energy directors and as telescopic distance supports. The distance to which the adjustment element is driven into the anchoring element serves to adjust the relative z position. Figure 58b and Fig.58cDifferent cross-sectional profiles are shown for the protrusions 221. The protrusions are arranged so that they do not form a closed contour so that air trapped between the components can escape.

[0448] Fig.59 A cross section of a corresponding arrangement after the welding process is shown.The degree to which the opening 228 between the anchoring part and the adjustment part 201 remains open depends on the relative z-position after the adjustment.

[0449] Fig.59 The adjustment component in FIG. 201 is shown for illustrative purposes to include a fastening portion 231 for clamping another object to the arrangement. Alternatively, as in other embodiments, the adjustment component 201 may include other structural or functional elements.

[0450] Instead of being initially different components, the adjustment component and the anchoring component can be provided as an already preassembled whole, the adjustment component being welded to the anchoring component. Next, the assembly of the two components is used as a first object. For the process, a (single) sonotrode acting on the proximal face is used to couple energy into the assembly and to press the assembly towards the second object. Due to the excellent energy-guiding properties of the edge of the second object, the thermoplastic material initially located at the interface with this edge will become flowable, and the assembly will be pressed into the part of the second object protruding towards the proximal side. Only when the distal face 12 reaches the planar component will the resistance increase and the area formed by the protrusion 21 will start to collapse until the desired relative z position is reached.

[0451] Fig.60 A variant is shown in which, in addition to the protrusion, a peripheral portion 222 of the adjustment component 201 at least partially surrounds a portion of the anchoring component (here: the first object 1). In this way, the guidance of the adjustment component during this step is simplified and another connection, such as a weld, can be formed along the periphery 223 of the surrounded portion of the anchoring component.

[0452] Fig.61a Another variant is shown, in which both the anchoring part 241 and the adjustment part 242 belong to the first object 1 and are formed as one piece with each other. A series of cavities 243 define a deflation zone between the anchoring part 241 and the adjustment part 242. For this process, the sonotrode 6 acting on the proximal face of the first object couples energy into the first object 1 and presses it towards the second object 2. Due to the excellent energy-conducting properties of the edge of the second object 2, the thermoplastic material initially located at the interface with this edge will become flowable, and the assembly will be pressed into the part of the second object protruding towards the proximal side ( Fig.61a). Only when the distal side 12 reaches the flat portion, the resistance will increase and the area formed by the protrusion 221 will begin to collapse until the desired z position is reached. Figure 61b shows the result of a collapsed area with a larger collapse. The degree to which the collapsed area is caused to collapse defines the adjustment of the z position.

[0453] refer to Figure 55-Figure 6 The embodiments described are all based on the fact that the fixing of the adjustment element relative to the anchoring element is material fixing, i.e. the adjustment element and the anchoring element are fused together after the process.

[0454] Instead of the concept described above of providing a connecting element (which can but need not be initially separated from the first object), an alternative set of embodiments is used to implement the concept of adjusting the z-position of the adjustment element relative to the anchoring element. If the connecting element is not initially separated, the corresponding element is also indicated herein as a "non-liquefiable material body". In this alternative set of embodiments, the relative position of the first object thermoplastic material body (which can constitute the entire first object) and the element (connecting element, non-liquefiable body) is adjustable in the process. Here, the connecting element serves as the adjustment element and the first object anchored relative to the adjustment element serves as the anchoring element.

[0455] Fig.62 A first embodiment of this is shown. The connector 3 and Figure 7 Similar is a nut with internal thread 39 and external retaining structure 31. For the adjustment and fixing step, the sonotrode 206 can be used, for example, after the step of fixing the first object 1 to the second object 2, to press the connecting piece into the first object and at the same time couple vibration energy into the connecting piece 3 so that the thermoplastic material part can flow and thus allow the connecting piece to move into the material of the first object. Once the connecting piece 3 has reached the desired z-position, the forward movement and energy input are stopped. After the thermoplastic material parts have resolidified, by their infiltration into the retaining structure, they locate the z-position and anchor the connecting piece in the material of the first object 1.

[0456] In the embodiment shown, the first object 1 is provided with an undersized (compared to the outside diameter of the connecting piece) opening 270 into which the connecting piece enters. Fig.62 As shown, the opening is not a through opening but is blocked by a bottom 271, so that the first object is provided with a seal as in the previously described embodiments to seal the proximal side of the second object from the distal side thereof.

[0457] Alternatively, something like Figure 7 The connecting piece 3 itself can make the opening with the thread not a through opening but a blind opening.

[0458] In a further alternative, as is the case in the examples described further below, a seal between the proximal and distal sides is not required.

[0459] Fig.63 A variant is shown, in which the opening 270 is a through opening and likewise the connecting element 3 is a nut having a through opening.

[0460] As Fig.63 According to another optional feature of the embodiment of the invention, the additional second sonotrode 206 which serves to press the connecting element into the first object and adjust the z-position does not act from the proximal side but from the distal side, i.e. not from the same side as the first sonotrode 6 which serves to fix the first object 1 to the second object 2.

[0461] Regardless of whether the z-position of the connector is adjusted proximally or distally, the screws or other fasteners subsequently secured to the connector may be placed proximally or distally.

[0462] Of course, instead of inserting / fixing by mechanical vibration effect, the connection piece 3 can be inserted into the first object by being pressed in or by simple screwing if it has a self-locking (external) thread. The concept of adjusting the z position independently of the fixing process remains the same.

[0463] Figure 64a and Figure 64b The embodiment in which the connector 3 has a gradually inclined portion that cooperates with the gradually inclined opening 252 of the first object is shown. The extent to which the gradually inclined portion of the connector 3 is pressed into the opening 252 by the ultrasonic welding electrode 206 defines the relative z position. As in the previous embodiments, the connector may include an outer coupling structure / retaining structure that cooperates with the liquefied and resolidified thermoplastic material portion to form a positive fit fixation of the connector relative to the first object 1.

[0464] exist Figure 64a and Figure 64b The following additional optional features shown in are not relevant to this concept and are independent of each other:

[0465] - the connecting element has a head forming a base for clamping connection to another component;

[0466] The first sonotrode 6 has a distal projection 62 for shaping and, for example, also at least partially forming the opening 252. Thus, the first object, before being fastened to the second object 2, initially has only an undersized preliminary opening 251, so that material of the first object is displaced by the first sonotrode 6 during the fastening to the second object 2.

[0467] Figure 64a and Figure 64bThe contents may work together with a through opening 252 or a gradually inclined blind opening.

[0468] exist Fig.65 In the embodiment shown, the connector is not merely an insert (as in the embodiment described above, in particular Figure 4a , Figure 5a , Figure 6-Figure 8 , Fig.15 , Figure 62-64b ) but rather has a peripheral flange portion surrounding and guiding the proximal portion of the first object. The peripheral flange portion can be provided with an inwardly facing retaining structure 31. Similarly, the middle portion, here with internal threads 39, can have such retaining structures facing outwardly to cooperate with the first object material into the opening into which the middle portion is pressed (see Fig.65 ).

[0469] Figure 66-Figure 68 Different engagement structures for inserts are shown. The insert may be, for example, Figure 55-Figure 6 1, the insert may be present in the adjustment part 201, so that the assembly of the anchoring part and the adjustment part can be used as an anchor for connecting the further part to the second object. Alternatively, the insert may be an insert of a non-liquefiable material body in the sense described above. As another alternative, the insert may be a connecting part in the sense discussed above, for example, used as an adjustment part.

[0470] exist Fig.66 In the embodiment, the insert is a nut having an internal thread and, for example, an external retaining structure. Fig.67 In the embodiment, the insert comprises a threaded rod to which a nut or other member can be threadedly connected. The anchoring member 191 is embedded in the thermoplastic material of the first object 1 or the adjustment member 201, respectively. Fig.68 Similarly, an insert with a fastening head for a clip-type connection is shown. Other configurations are of course also possible.

[0471] Instead of being fastened to the thermoplastic material by having a portion embedded therein, other connections including removable connections may also be formed. For example, the insert and the first object / adjustment component may be provided with a snap-fit ​​engagement structure, whereby the insert may be inserted into an engagement groove and secured by a twisting motion.

[0472] The above has been described mainly with reference to embodiments in which the first and second objects are fixed to each other before the step of adjusting the z-position is performed to adjust the z-position of the adjustment member relative to the anchoring member. In such embodiments, the steps of fixing and adjusting can be selectively performed at different locations, for example at different stations of a production line.

[0473] According to another set of embodiments. The z position may be adjusted prior to fixation. For example, initial detection data on details of the second object (or an assembly including the second object) and / or details of any other components (the first object, other objects to be fixed to the first object) may be obtained. Based on this, the desired z-adjustment may be pre-calculated. Next, the z-adjustment may be implemented, for example, based on any of the contents described herein. Fixation occurs in these embodiments only after the z-adjustment has been implemented.

[0474] This subconcept can be used to differentiate steps in the processing. In particular, this is advantageous if the second object 2 is relatively large or belongs to a relatively large prefabricated component (such as a car body), because the z-adjustment step can then be carried out at a smaller station without delaying the main process. This principle is shown very schematically in Figure 107, where 450 represents a z-adjustment station and 451 represents a fixing station.

[0475] Fig.121 A flow chart showing a possible process according to an embodiment of the invention comprising adjusting the position of a connection relative to a second object (or the like), for example for tolerance compensation.

[0476] After the start (S), possible tolerance mismatches are detected in a first step 701. Next, the correct position or position correction is calculated (step 702). If the connector or other functional component belongs to the first object and is integrated with it, then the first object and the second object are then positioned relative to each other in the calculated correct position x, y, z (angle) (step 703); for example, minus the z-offset representing the relative movement of the first and second objects in the following steps. Next, a fixing step 704 for fixing the first object to the second object is carried out as described herein.

[0477] However, if the connection comprises an anchoring part and an adjustment part (if it is not a single piece or comprises, for example, a collapsible / expandable area), a further distinction is made. In a first group, the position of the adjustment part relative to the anchoring part is adjusted (step 706) and positioned (step 707) before a fixing step 708 of the anchoring part to the second object. The optionally combined adjustment / positioning step can be performed at the same or a different station than the subsequent fixing step.

[0478] In the second group, first a fixing step 7011 of fixing the anchoring member to the second object is performed, followed by a (recombinable) adjustment and positioning step.

[0479] In both groups of embodiments, the positioning step and possibly also the adjustment step may be combined with the fixing step as explained above.

[0480] In the second group of embodiments, unlike what is shown in the flow chart, the detection and calculation steps 701 , 702 may be performed after the fixing step 711 .

[0481] In embodiments with or without z-adjustment, the extension of the connection in the z-direction may be a problem. For example, the first object may be a connector or be part of a connector that is used to fasten another object to a second object, and this other object needs to be relatively close to the second object (low height connection).

[0482] For example Fig.62 , Fig.63 , Figure 64b , Fig.65 The embodiment solves this problem by providing the first object with an extension portion that extends into the perforation 20 of the second object and through the plane of the sheet (if defined), and by providing this portion of the first object with, for example, a retaining structure (internal thread 39) or other attachment structure to secure the further object to the second object via the first object.

[0483] Fig.116 A further embodiment is shown. The first object has Fig.62 Unlike this embodiment, an anvil 600 is used. The anvil includes a guide protrusion located radially inward of the edge (with reference to the center of the perforation) that guides the material to flow toward the distal side of the second object, toward the radial outward flow into the annular receiving recess 602. The anvil includes a groove for receiving the extension 268 extending into the perforation and including the opening 270.

[0484] Fig.116 The ultrasonic welding electrode 6 shown includes a guide protrusion 62 that cooperates with the opening 270 to guide the ultrasonic welding electrode and further implement the following, for example, with reference to Fig.87 Both of these features are related to Fig.116 The features of the embodiments are not relevant but help to optimize the fixing process.

[0485] Fig.117 Another embodiment is shown (in Fig.117 116 , an anvil is used to direct the material flow, the anvil having a recess for accommodating the extension 269 (which may alternatively be a through opening for the embodiment shown).

[0486] exist Fig.117 The possible principle of any embodiment including an anvil is also shown in FIG. The volume of the recess 602 (in Fig.117 ) can be chosen to be slightly smaller than the volume of the thermoplastic material portion available for flow. Fig.117 In the embodiment, this available material portion corresponds to the volume of the annular protrusion 605 of the first object. If the volume of the receiving structure of the anvil is smaller than the available volume of the thermoplastic material, an advantageous forming pressure can be achieved by applying pressure to the first object on the one hand and to the second object and the anvil on the other hand.

[0487] exist Fig.111 and Fig.112 Another option is briefly described in . The second body comprises, in addition to at least one perforation 20 (three perforations 20 in the illustrated embodiment) along which the edge 21 extends, an extended opening 510 .

[0488] Unlike the position of the perforations, the second body does not protrude along the extension opening 510 towards one side of the first body. The z-extension of the first body around the extension opening can thus be freely selected according to requirements. Likewise, the shape and size of the fastening opening are selected independently of any desired properties of the fixing process.

[0489] exist Fig.111 and Fig.112 In the embodiment of the invention, the first object 1 has an extension portion extending into the opening through the mouth of the extension opening 510, which is a collar 512. As shown, the collar is generally tubular. The connector 3 extends into the extension opening. The connector 3 cooperates with the binding element 530 to fix another object 501 to the second object. Therefore, the binding element 530 is shown to have a head 531 to clamp another object 501 to the connector. Other structures for fixing another object 501 to the connector can be used alternatively or as a supplement to the structure shown.

[0490] The connector 3 comprises a head 521 and a shaft 522, as indicated by the double arrow Δz, wherein the shaft can be fixed to the collar 512 at different z positions. The mechanical connection between the collar 512 (more generally: the first object) on the one hand and the shaft 522 (more generally: the connector 3) on the other hand can be any suitable connection, including a threaded connection, other types of form-fitting connections and / or force-fitting connections, material connections (e.g., fusion or adhesive connections or welding connections), etc.

[0491] Fig.112 It is also shown that the size of the ring extending through the mouth of the extension opening 510 may enable slight adjustments to the in-plane position (xy-position) of the first object relative to the second object.

[0492] Fig.113 Shows Fig.111 and Fig.112 A variation of the construction in which the following additional features are implemented:

[0493] The second object 2 and / or the further object need not be planar but have any 3D shape. Accordingly, a sheet plane is defined only locally around the perforations 20 and around the extension opening. The shape of the first object is adjusted accordingly.

[0494] The extension of the first object extending through the mouth of the extension opening and away from one side of the further object 501 is not a collar open towards this side, but a collar 512 closed towards this side by a bottom 513 .

[0495] - The first object 1 is not made of a thermoplastic material but comprises a first part (body) which constitutes a functional area 111 and a second part which constitutes an attachment area 112. The functional area can consist of a different material than the attachment area, in particular a non-thermoplastic material. Thus, the functional area material can, for example, have excellent dimensional stability. In particular, the functional area can be metallic or consist of a harder plastic material, such as a composite material, than the thermoplastic material of the attachment area.

[0496] In particular, the second part 112 constituting the attachment region can be held relative to the first part constituting the functional region by a shape fit selectively in addition to other connections, such as adhesive connections. Fig.113 , the first portion is shown having an undercut recess that is filled with the thermoplastic material that constitutes the second portion 112.

[0497] -exist Fig.113 In the figure, the first object 1 is shown to form a fastening structure with an internal thread that cooperates with the external thread of the connecting member. Other fastening structures including a series of snap-fit ​​structures at different depths, glue channels, etc. are also possible.

[0498] These features are independent of one another, ie it is possible to realize them individually or in any combination.

[0499] refer to Figure 73-Figure 79 , describes the principle of providing the contact side with a structure, for example a pattern of recesses and protrusions, to reduce the required energy and force input.

[0500] Fig.73 An arrangement of a first object 1, a second object 2 and a sonotrode 6 positioned on the near side of the first object 1 is shown. The first object has a pattern of protrusions 301 on the contact side (the far side in the arrangement shown) and a pattern of recesses 302 between the protrusions. Thus, the flow portion of the thermoplastic material flowing relative to the second object has space to flow in during the process. This is different from embodiments without structures on the contact side, where excess material displaced by the second object must either be squeezed out through perforations or through the sides, or must flow back towards the second object against the direction of pressure, in which case the forces and energies to be applied are higher.

[0501] like Fig.74 Shown in more detail, the following possible design criteria may apply:

[0502] The total volume V1 of the protrusion is approximately equal to the total volume V2 of the recess, ie the mid-plane of the contact side surface is approximately equidistant from the peak of the protrusion and the valley of the recess, respectively.

[0503] The depth hi of the recess is smaller than the height h2 of the protruding section. This design criterion applies in particular when the connection between the first and the second object has to be sealed.

[0504] These guidelines are independent of each other.

[0505] Fig.75 and Fig.76 A view of the first object 1 from the contact side is schematically shown, illustrating a possible pattern of indentations / protrusions. Fig.75 The radial pattern of comprises recesses 302 and protrusions 301 extending radially from a central portion 304 which in this step is aligned with the perforations of the second object and has a smaller diameter than the latter. Fig.76 A checkerboard pattern is shown.

[0506] Figure 77-Figure 79 Alternative cross-sections of protrusions forming a pattern of protrusions and recesses are shown. Fig.77 The cross-sectional shape is similar to Fig.73 and Fig.74 Rectangular but slightly tapering. Fig.78 A sharp angled shape is shown which has energy directing properties (in many embodiments the energy directing properties of the edge of the second object are sufficient, but additional energy directing properties of the first object may be advantageous in some cases). Fig.79 A combination of a rectangular cross-section body including protrusions 301 plus energy directing ridges 305 is shown.

[0507] Fig.80 and Fig.81 An embodiment of a second object is shown having a main aperture 20 and a plurality of peripheral apertures 310 distributed along the periphery of the main aperture. Fig.80 shows a top view of a second object, Fig.81 The first object 1 is shown attached to the second object 2 after the process. These peripheral perforations are smaller than the main perforations and are arranged in a section of the second object protruding proximally away from the sheet plane of the second object, i.e. these peripheral perforations are arranged in a position where the sheet is inclined relative to the sheet plane (see Fig.81 ). In addition, Fig.81As shown, the sheet is deformed to protrude away from the curved surface defined by the protruding segment, particularly proximally, along one or more peripheral perforations, where the peripheral perforation deformed segment 313 is shown to bend proximally relative to the dashed line representing the curved surface.

[0508] Fig.82 An embodiment is shown in which the second body deformation section is asymmetrical along the periphery, in that the height h of the protruding section varies as a function of the position along the edge of the second body. In the cross-sectional view shown, the relationship 0≤h1<h2<d z Established.

[0509] For example, if asymmetric loads are expected to be applied to the joints between objects, then something like Fig.82 The asymmetric deformation section in the is desirable. The asymmetric deformation section may also exist due to processing conditions. For example, the fastening axis (proximal-distal axis; Fig.82 The vertical axis in (a) may be different from the deformation axis, especially if the second object is not just planar but has a more complex, large-scale 3D shape. Fig.83 This is illustrated very schematically by showing a punching tool 320 which causes a perforation and a deformation which results in a deformed section around the perforation.

[0510] If the deformation section does not extend around the entire periphery, ie if there is a portion with h=0, then one possible condition is that the deformation section is such as Fig.84 The diagram shows an extension of more than 180° around the periphery. However (see, for example, Fig.15 ), this need not be the case depending on the application and construction.

[0511] Fig.85 The possibility of controlling the z-position by appropriately shaping the contact side of the first object is shown. The first object has a distally facing foot 341, which is located peripheral to the position where it contacts the edge of the second object. The foot is also placed more laterally than the protruding section of the second object, thereby causing relative movement of the first and second objects towards each other when the first and second objects are pressed towards each other when vibration is applied, until the foot abuts the sheet at the point where the sheet plane is defined. The z-position of the first object relative to the second object is thus defined by the size of the foot acting as a spacer.

[0512] Fig.86 A simplified flow chart is shown. When the foot abuts the second object (dashed line), the pressure F (shown as a function of relative position) required to move the first and second objects relative to each other increases significantly, which can be used to define a threshold force F t .Once the required force reaches a threshold level, the process stops.

[0513] Fig.87 The principle of defining the coupling surface between the sonotrode 6 and the first object 1 to a region whose in-plane (xy-) extension is defined to a region designed according to the shape of the second object and the position of the edge is shown. For example, the coupling surface can be defined to track the path of the edge of the second object 2. In an embodiment with a perforation formed along it, the coupling surface is annular with a central opening.

[0514] Therefore, in Fig.87 The middle sonotrode is formed to include a distal annular protrusion 331 , thereby forming an intermediate hollow space 332 in the process.

[0515] like Fig.88 As shown, a schematic vertical protection is shown, and the coupling surface 333 (dashed line) extends to both sides of the edge 21.

[0516] A configuration with a sonotrode formed with a hollow space may have the additional advantage that it becomes possible for a functional element to be arranged centrally relative to the through-hole 20 without direct contact with the sonotrode. Fig.89 An example of a first object comprising a connecting member 3 as a threaded rod is shown, while Fig.90 A first object is shown having a bushing as connecting element 3 .

[0517] Fig.91 The principle of defining the coupling surface does not need to be implemented by correspondingly designing the shape of the sonotrode, but the shape of the proximal side of the first object 1 can be designed to define the coupling surface in addition or alternatively. Fig.91 In the embodiment, the first object forms a notch 335 that is aligned with the perforation 20 in the second object 2. Fig.91 In the figure, the distal coupling-out face of the sonotrode 6 is shown as being substantially flat; other shapes are also possible, such as including a guide protrusion (not shown) that engages with a guide recess of the first object.

[0518] In one set of embodiments, also possibly but not limited to embodiments wherein the coupling surface is adapted to the perforation location and edge, the method comprises adjusting the position, in particular the in-plane (xy-) position of the first object and / or of the sonotrode relative to the second object.

[0519] In a first subgroup of this set of embodiments, the position of the sonotrode 6 relative to the second object 2 is defined, for example, by a machine comprising a mounting frame. Fig.92 The position of the first object 1 which can be arranged between the sonotrode and the second object 2 is adjustable. The accuracy (needed via the adjustment of the position of the first object) depends greatly on the nature and function of the first object and on the requirements.

[0520] A second subgroup of embodiments consists in defining the position of the first object 1 relative to the sonotrode 6. The position of the first object-sonotrode assembly relative to the second object is adjustable. The accuracy (needed via adjustment of the xy-position) also depends greatly on the construction and on the requirements. Fig.93 The principle of the second subgroup is schematically shown. The relative in-plane (xy-) position of the sonotrode and the first object is located by the cooperation of the guide protrusions 62 of the sonotrode with the corresponding guide protrusions of the first object. However, there are other means for defining the relative in-plane position.

[0521] Fig.94 and Fig.95 The first subgroup is concerned and shows a possible arrangement for supporting and positioning a first object for the method. The principle shown is similar to that in Fig.50a and Fig.50b One possible requirement is that the means for guiding the first objects need to be vibrationally decoupled from the frame on which they are respectively mounted (e.g. consisting of a support frame or a box). Fig.50a and 50b In this case, the shape of the guide tool is used. As an alternative to them, Fig.94 and 95 The guide means are shown as springs 361 mounted on adjustment means 362, at least some of which have an adjustable xy-position. The arrangement may for example comprise three or four such adjustment means 362, the springs being distributed around the periphery of the first object 1. In case there are four adjustment means, the adjustment means located in opposite positions may be connected to each other and may be moved together.

[0522] Figure 96-Figure 100 The second subgroup of embodiments relates to the structure for defining and positioning the in-plane position of the first object 1 relative to the sonotrode 6 for the method. Fig.96 The sonotrode may be provided with a suction channel 371 through which a vacuum may be applied, whereby the first object may be caused to temporarily be attracted to the proximal side of the sonotrode. Fig.97 At least one such suction channel 371 is shown in combination with a possible positioning. Fig.97 The sonotrode 6 of 1 comprises, for example, a guide tip 373 which penetrates the first object 1 and thereby locates the lateral position. The penetration into the first object can be caused by a vacuum applied to the suction channel and / or by pressure, possibly also with the aid of vibration. In the latter case, the material of the first object can be made locally flowable in order to make the guide tip penetrate by the energy input.

[0523] If, instead of a pointed guide tip 373, the sonotrode (or first object) comprises an annular ridge, the pressing of the first object and the sonotrode towards each other also solves the problem of leakage that may occur when coupling vibrations into the sonotrode. Otherwise, the pumping rate must be sufficient to compensate for this leakage in order to maintain the vacuum.

[0524] The guide tip 373 or other penetration guide need not be undercut. In the latter case, for example in a Morse cone-shaped case (the shape of the guide means being appropriately chosen), in-plane guidance and possibly also temporary overall positioning may result from guiding the tool into the material of the first object.

[0525] After the guide tip (or other penetration guide tool) has penetrated the first object, the vacuum device that draws the first object toward the sonotrode 6 can be turned off.

[0526] Fig.98 Another possibility is shown. A guide 381 (here a guide rod) is guided laterally both relative to the sonotrode 6 and relative to the first object 1. A first bearing 382 in the sonotrode is formed by an O-ring which is a loose-fitting bearing. A second bearing 383 is a tight-fitting bearing relative to the first object, wherein the guide is also held against axial movement by the second bearing. Since one of the bearings (in the embodiment shown, the first bearing 382) is only a loose-fitting bearing, vibrations transmitted through the guide can be minimized.

[0527] exist Fig.99 In a variant of the invention, both the first bearing 382 and the second bearing 387 are loose-fitting bearings. The axial support is given by the inward flange 385 of the sonotrode 6 and the outward flange 384 of the guide 381 cooperating with an O-ring constituting a first bearing preventing the guide 381 from loosening from the sonotrode 6. An optional spring 388 ensures that the axial position relative to the sonotrode remains well-defined. Fig.99 The guide member 381 of the embodiment is similar to Fig.98 384, is generally cylindrical except for the outward flange 384. This cylindrical symmetry is not necessarily the symmetry of the rotating drum; deviations from rotational symmetry can result in guidance of relative movement also with respect to rotation.

[0528] Fig.100 An embodiment is shown in which the first object is guided by a peripheral flange 391 of the sonotrode as an alternative (supplement) to the guide protrusions. The dashed line shows an optional additional conical penetration guide 392 which can penetrate into the material of the first object during the process.

[0529] Fig.101The figure shows that the contact force between the first object and the object pressed by the sonotrode, i.e. the second object, varies periodically when the sonotrode couples mechanical vibrations into the first object. In the lower half-wave (shown by the shaded area), the contact is very weak or even loose, which can cause uncontrolled lateral movement ("wandering") of the first object in the process without a guiding tool. This can be solved by pressing the sonotrode against the first object with greater force. However, this affects the vibration coupling properties and the pressure is therefore a parameter that cannot be chosen arbitrarily. However, if the additional pressure F p The problem is solved if this additional pressure is sufficient to compensate for the "lifting" effect during the second half-wave. Fig.101 ).

[0530] exist Fig.102 , in which a pressing tool 395 is shown in addition to the sonotrode. The pressing tool has an optional peripheral guide flange in the embodiment shown. The sonotrode is also shown with at least one conical penetration guide 392, which is also optional.

[0531] For this method, it is sufficient if the clamping tool 395 acts on the first object in the initial stage. Once the edge of the second object has penetrated a certain depth into the first object, the clamping force is no longer required. Therefore, when the first object is moved distally in the process, the clamping tool does not necessarily need a forward driving mechanism to maintain pressure.

[0532] Fig.102 An embodiment of the invention may belong to the second subgroup, or it may belong to another subgroup in which the predetermined positions of the first and second objects relative to each other (the position of the first object being positioned by the clamping tool) and the ultrasonic welding electrode position are adjustable.

[0533] Fig.103 A fastener 400 is shown having an anchor plate 401 (or "fastening head") and a fastening element 402 bonded thereto. The fastening element may have any of the properties of a prior art fastener, such as a threaded bolt (as shown), a rod without threads, a pin, a nut, a hook, an eyelet, a base for a bayonet connection, etc. The fastener may here consist essentially of a fastener sold under the trade name "bighead" and is intended to be bonded to the surface of another object.

[0534] This type of fastener can be used as a second object in the process of the invention. The anchoring plate 401 can be regarded in particular as a sheet and can be provided with a plurality of openings 403 along which edges extend. This edge and / or the peripheral edge of the anchoring plate can be used as an edge in the method according to an embodiment of the invention. Thus, the anchoring plate can be deformed to be curved along the corresponding edge, in particular curved towards the side of the first object which is in contact with the anchoring plate for the method.

[0535] Fig.104 A first possibility is shown very schematically, wherein the situation allows the mechanical vibration to be applied from the side of the first object 1. The anchoring plate 401 is bent towards the first object side (for example but not necessarily corresponding to Fig.103 oriented bottom side), whereby a bond can be formed, in particular in the region of the opening(s) 403 as indicated above.

[0536] In many reference Fig.103 In the construction of fasteners of the type described, coupling vibrations into the first object is not possible or is disadvantageous, for example because the first object is a larger object, its back side is not easily accessible, and / or for other reasons. Subsequently, the vibrations can be coupled into the second object. Therefore, the shape of the sonotrode for coupling vibrations into the component can be designed appropriately.

[0537] Fig.105 A first possibility is shown very schematically. The sonotrode has a receiving opening 410 which has a mouth in the distal coupling-out face, wherein the fastening element 402 is received when the distal coupling-out face is pressed against the anchoring plate. The tool (sonotrode) and the second object are thus adapted to one another so that the tool is pressed directly against the proximally facing surface of the anchoring plate.

[0538] The tool may be provided with a guide structure, such as an inwardly directed guide projection 411 for guiding the second object relative to the tool. This guide structure may in particular be engaged to a fastening element, such as in Fig.105 Like the guide protrusion 411 schematically shown in the embodiment shown in FIG.

[0539] In an embodiment, the guide structure can be configured as a fastening structure cooperating with a fastening element to temporarily fasten the second object (fastener) 2 to the sonotrode 6. This possibility is Fig.106 It is shown schematically in Fig.106 In the example of the second object / fastener, the second object / fastener has a fastening structure 402 for fixing a nut, for example, which is welded to an anchor plate 401, and this nut serves as the fastening structure. The tool 6 comprises a threaded protrusion 421 adapted to the internal thread of the nut 402, whereby for the method the connector can be screwed onto the tool.

[0540] Similar configurations are possible for other fastening elements, such as recesses with internal threads for cooperating with a threaded shank of a fastener.

[0541] In the embodiments described above, the mechanical vibrations are assumed to be longitudinal vibrations, i.e. vibrations in the proximal and distal directions. This is not necessary. For example, as is known from ultrasonic welding of metal parts, the vibrations can also be transverse vibrations, which in the context of the present invention are an option in particular for embodiments in which the vibrations are coupled into the metal part, i.e. into the second object instead of the first object. For example, similar to reference Fig.106 The embodiments described, in which there is a second object temporarily fastened to the sonotrode, make it possible to couple transverse vibrations from the sonotrode into the second object.

[0542] Fig.108 An alternative is shown very schematically. The sonotrode couples vibrations into the second object from a generally lateral direction (if defined, in-plane direction with respect to the sheet plane) so that a separate pressure tool 470 applies the required pressure. This arrangement corresponds to a lateral drive arrangement in ultrasonic metal welding.

[0543] Fig.109 A sonotrode 6 configured for transverse oscillation is shown. The sonotrode 6 has a receiving opening 410 designed to receive the fastening structure 402. Fig.109 The receiving opening is shown with an internal thread adapted to the thread of the fastening structure, which is a threaded rod. The sonotrode 6 has an annular skirt 480, which is pressed against the outer portion of the anchoring plate during the process and thus, together with the receiving opening, couples pressure and mechanical vibrations into the anchoring plate 401. For reasons of symmetry, Fig.109 The sonotrode 6 shown in FIG. 4 has a proximal annular skirt 481 in addition to a distal annular skirt 480 pressed against the anchoring plate. It is thus possible to carry out the process for two parallel assemblies, the sonotrode being clamped between two first objects pressed against a corresponding second object introduced from the opposite side (the length of the corresponding fastening structure should then of course correspond to at most half of the extension of the sonotrode in the direction of the receiving opening). Fig.109 The two or more coupling locations in the drawing plane should be located on opposite sides of the sonotrode.

[0544] Another sonotrode 6 suitable for a "Wedge-Reed"-like configuration is provided, for example, Fig.110 The ultrasonic welding electrode includes a receiving opening 410 for receiving a fastening structure (eg, a threaded rod). Fig.109 and 106In an embodiment, the receiving opening can be selectively configured to couple to a fastening structure. The sonotrode is configured and mounted for lateral vibration of the distal portion, for example by coupling vibration into the sonotrode via a side-acting coupler and causing bending oscillations of the sonotrode, such as Fig.110 Shown schematically.

[0545] In the embodiment shown, the sonotrode comprises a plurality of wings instead of an annular skirt for coupling vibrations into the lateral portions of the anchoring plate. Fig.109 The adaptation of a sonotrode with an outer coupling skirt or with another coupling surface can be easily realized.

[0546] Although the lateral movement option has been described primarily with reference to a second object being a fastener with an anchor plate, the concept is readily applicable to other embodiments, particularly embodiments in which vibrations are coupled to the second object, including the embodiments of FIGS. 25-26 , 30 - 31 , etc.

[0547] Example 1:

[0548] An ABS disc with a thickness of 4 mm and a diameter of 19.5 mm was attached to the Figure 1a and 1b The deformed metal sheet is a 0.8 mm steel sheet. The major diameter D varies between 6, 8 and 12 mm, the height h is set to a value between 2 mm and 3 mm, and the angle α is selected to be 20°. A commercially available ultrasonic welding device (20 kHz) operating at an amplitude of about 60 μm and a required energy of 1000-1500 W is used, which is pressed against the proximal end face of the disk under a force starting from 100 N and peaking at about 400 N. Figure 3a and 3b The method shown results in a solid connection and, after cooling to room temperature, the disc cannot be torn off from the sheet without deforming the sheet.

[0549] Repeat the same operation by systematically varying the parameters, i.e.

[0550] -1.2mm aluminum sheet instead of steel sheet.

[0551] - Angle 40°

[0552] -Height 1.8mm

[0553] - Polyamide 66 with 30% Vol glass fiber as disc material

[0554] -PVC, PBT, PET and PC2000 as disc materials;

[0555] -like Figure 2a and 2bThe perforations shown have a smooth shape.

Claims

1. A method for mechanically fixing a first object to a second object, the method comprising the following steps: - providing said first object comprising a thermoplastic material in a solid state; - providing a second object having a substantially planar sheet with an edge, the sheet having a perforation, the edge extending along the perforation and the sheet having a section along the edge protruding away from the plane of the sheet; - positioning the first object relative to the second object to provide an assembly comprising the first object and the second object, in which assembly the edge is in contact with the thermoplastic material; - when the rim is in contact with the thermoplastic material, coupling mechanical vibration energy into the component until a flow portion of the thermoplastic material becomes flowable due to frictional heat generated between the rim and the thermoplastic material and flows around the rim to at least partially embed the rim within the thermoplastic material; - Stopping the mechanical vibration and allowing the thermoplastic material to resolidify, whereby the resolidified thermoplastic material at least partially embedded in the edge anchors the first object into the second object; It is characterized in that the first body comprises a contact side with the thermoplastic material, wherein during the positioning step, within the component, the edge is in contact with the contact side and the contact side is structured by comprising protrusions and / or recesses.

2. The method of claim 1, wherein the contact side comprises a pattern or ridges and grooves.

3. The method of claim 2, wherein the ridges and grooves extend radially from a center, and the positioning step includes aligning the center with a perforation of the second object.

4. A connector suitable for use in the method according to any one of claims 1 to 3, the connector comprising: • a contact side and a back-facing side, the back-facing side facing away from the contact side with respect to the z-direction, • a thermoplastic material in a solid state at least at the attachment site on the contact side, • wherein the connector is securable to a second object by a method, the second object having a generally planar sheet with an edge, the sheet having a perforation, the edge extending along the perforation, and the sheet having a section along the edge protruding away from the sheet plane, the method comprising coupling mechanical vibration energy into at least one of the connector and the second object when the contact side and the second object are pressed against each other until a flowable portion of the thermoplastic material becomes flowable due to frictional heat generated between the edge and the thermoplastic material and flows around the edge to at least partially embed the edge within the thermoplastic material; • the connector further comprising a fastening structure configured to cooperate with a fastening structure of a further object to secure the further object to the connector and thereby connect the further object to the second object; The contact side is structured in this case by comprising elevations and / or recesses.

5. A method of mechanically securing a first object to a second object, the method comprising the steps of: - providing said first object comprising a thermoplastic material in a solid state; - providing a second object having a substantially planar sheet with an edge; - positioning the first object relative to the second object to provide an assembly comprising the first object and the second object, in which assembly the edge is in contact with the thermoplastic material; - when the rim is in contact with the thermoplastic material, coupling mechanical vibration energy into the component until a flow portion of the thermoplastic material becomes flowable due to frictional heat generated between the rim and the thermoplastic material and flows around the rim to at least partially embed the rim within the thermoplastic material; - Stopping the mechanical vibration and allowing the thermoplastic material to resolidify, whereby the resolidified thermoplastic material at least partially embedded in the edge anchors the first object into the second object; It is characterized in that in the step of providing the second object, the sheet portion of the second object includes a through hole, the edge extends along the through hole, and the sheet portion has a section along the edge protruding away from the sheet plane, and the ultrasonic welding electrode and the first object are adapted to each other so that the coupling surface covers the in-plane position of the edge but does not extend to the center position relative to the through hole.

6. The method of claim 5, wherein the contact surface forms a trajectory around a center, the in-plane position of the center corresponding to the in-plane position of the perforation.

7. A kit comprising at least one of the following: a sonotrode and a first object comprising a thermoplastic material in a solid state, wherein said sonotrode and said first object are adapted to each other to form a coupling surface around a central recess of said sonotrode and / or said first object; a sonotrode and a second object comprising a perforation and a substantially flat sheet with an edge, said edge extending along said perforation, and said sonotrode and said second object being adapted to each other such that said coupling face of the sonotrode covers an in-plane position of said edge but does not extend to a central position relative to said perforation; - comprising a first object of thermoplastic material in a solid state and a second object comprising a perforation and a substantially flat sheet with an edge extending along the perforation, and the first object and the second object are adapted to each other so that the coupling surface of the first object covers the in-plane position of the edge but does not extend to a central position relative to the perforation.

8. A method of mechanically securing a first object to a second object, the method comprising the steps of: - providing said first object comprising a thermoplastic material in a solid state; - providing a second object having a substantially planar sheet with an edge, the sheet having a perforation, the edge extending along the perforation and the sheet having a section along the edge protruding away from the plane of the sheet; - positioning the first object relative to the second object to provide an assembly comprising the first object and the second object, in which assembly the edge is in contact with the thermoplastic material; - when the rim is in contact with the thermoplastic material, coupling mechanical vibration energy into the component until a flow portion of the thermoplastic material becomes flowable due to frictional heat generated between the rim and the thermoplastic material and flows around the rim to at least partially embed the rim within the thermoplastic material; - stopping the mechanical vibration and allowing the thermoplastic material to resolidify, whereby the resolidified thermoplastic material at least partially embedded in the rim anchors the first object into the second object, providing an anchoring member and an adjustment member, wherein at least the anchoring member belongs to the first object; · adjusting the z-position of the adjustment member relative to the anchoring member; and • securing the adjustment member relative to the anchoring member when the adjustment member is in the adjusted position.

9. The method according to claim 8, wherein: The adjustment member is rotatable relative to the anchoring member, and the ramp section of the adjustment member is located above the ramp section of the anchoring member, so that rotation of the adjustment member relative to the anchoring member causes a shift in the relative z position.

10. A device, suitable for use in the method according to any one of claims 8 to 9, comprising: - an anchoring member, wherein the anchoring member comprises a contact side and an opposite side opposite to the contact side with respect to the z-direction, and comprises a thermoplastic material in a solid state at least at an attachment site of the contact side, whereby the anchoring member can be fixed to the second object by a method in which the second object has a substantially flat sheet with an edge, the sheet having a perforation, the edge extending along the perforation, and the sheet having a section along the edge protruding away from the sheet plane, the method comprising coupling mechanical vibration energy into at least one of the anchoring member and the second object when the contact side and the second object are pressed against each other; and - regulating components; - wherein the adjustment member and the anchoring member are configured such that the z-position of each other is adjustable and the adjustment member is fixable relative to the anchoring member, these members having an adjustable relative z-position.

11. A method of mechanically securing a first object to a second object, the method comprising the steps of: - providing said first object comprising a thermoplastic material in a solid state; - providing a second object having a substantially planar sheet with an edge, the sheet having a perforation, the edge extending along the perforation and the sheet having a section along the edge protruding away from the plane of the sheet; - positioning the first object relative to the second object to provide an assembly comprising the first object and the second object, in which assembly the edge is in contact with the thermoplastic material; - when the rim is in contact with the thermoplastic material, coupling mechanical vibration energy into the component until a flow portion of the thermoplastic material becomes flowable due to frictional heat generated between the rim and the thermoplastic material and flows around the rim to at least partially embed the rim within the thermoplastic material; - Stopping the mechanical vibration and allowing the thermoplastic material to resolidify, whereby the resolidified thermoplastic material at least partially embedded in the edge anchors the first object into the second object; The method is characterized in that the step of coupling mechanical vibration energy into the component includes coupling at least a portion of the mechanical vibration energy into the first object, wherein in the positioning step, the first object is brought into contact with the second object from a generally proximal side, and the step of coupling energy into the component includes pressing a vibrating sonotrode against a proximally facing coupling surface of the first object, thereby simultaneously coupling pressure and mechanical vibrations associated with the second object into the first object through the sonotrode.

12. The method of claim 11, wherein in the step of providing the second object, the second object comprises a perforation, the edge extending along the perforation.

13. The method of claim 12, wherein the first object is configured to seal the proximal side of the second object from the distal side of the first object by sealingly closing the perforation.

14. A method of mechanically securing a first object to a second object, the method comprising the steps of: - providing said first object comprising a thermoplastic material in a solid state; - providing a second object having a substantially planar sheet with an edge; - positioning the first object relative to the second object to provide an assembly comprising the first object and the second object, in which assembly the edge is in contact with the thermoplastic material; - when the rim is in contact with the thermoplastic material, coupling mechanical vibration energy into the component until a flow portion of the thermoplastic material becomes flowable due to frictional heat generated between the rim and the thermoplastic material and flows around the rim to at least partially embed the rim within the thermoplastic material; - Stopping the mechanical vibration and allowing the thermoplastic material to resolidify, whereby the resolidified thermoplastic material at least partially embedded in the edge anchors the first object into the second object; wherein the second object is a metal sheet or wherein the flat sheet portion is a metal sheet; The metal sheet is a metal sheet of a transport mechanism and the step of providing a second object comprises providing a metal sheet of the transport mechanism.

15. A method of mechanically securing a first object to a second object, the method comprising the steps of: - providing said first object comprising a thermoplastic material in a solid state; - providing a second object having a substantially planar sheet with an edge, the sheet having a perforation, the edge extending along the perforation and the sheet having a section along the edge protruding away from the plane of the sheet; - positioning the first object relative to the second object to provide an assembly comprising the first object and the second object, in which assembly the edge is in contact with the thermoplastic material; - when the rim is in contact with the thermoplastic material, coupling mechanical vibration energy into the component until a flow portion of the thermoplastic material becomes flowable due to frictional heat generated between the rim and the thermoplastic material and flows around the rim to at least partially embed the rim within the thermoplastic material; - Stopping the mechanical vibration and allowing the thermoplastic material to resolidify, whereby the resolidified thermoplastic material at least partially embedded in the edge anchors the first object into the second object; The first object comprises a main body of non-liquefiable material in addition to thermoplastic material.

16. The method of claim 15, wherein the step of coupling mechanical vibration energy into the assembly is performed such that, during the step of resolidifying the flow portion, the body extends through a plane defined by the rim.

17. A method of mechanically securing a first object to a second object, the method comprising the steps of: - providing said first object comprising a thermoplastic material in a solid state; - providing a second object having a substantially planar sheet with an edge; - providing a third object; - wherein the first object, the second object and the third object are positioned relative to each other to provide an assembly comprising the first object, the second object and the third object, wherein in the assembly the edge can be in contact with the thermoplastic material; - coupling mechanical vibration energy into the component when the edge is in contact with the thermoplastic material until: * the flow portion of the thermoplastic material becomes flowable due to frictional heat generated between the rim and the thermoplastic material and flows around the rim to at least partially embed the rim into the thermoplastic material; * causing the third object to be at least partially embedded in the thermoplastic material of the first object; - stopping the mechanical vibration and resolidifying the thermoplastic material, wherein the resolidified thermoplastic material at least partially embedded in the rim anchors the first object into the second object and thereby the resolidified thermoplastic material anchors the third object relative to the first and second objects.

18. The method of claim 17, wherein the third object comprises a generally planar sheet having a third object edge, wherein the step of coupling mechanical vibration energy into the assembly comprises coupling mechanical vibration energy into the assembly until the flow portion of the thermoplastic material becomes flowable and flows around the edge to at least partially embed the edge within the thermoplastic material and flows around the third object to embed the third object edge within the thermoplastic material.

19. The method according to any one of claims 17 to 18, wherein in the positioning step, the second object and the third object contact the first object from opposite sides.

20. A method of mechanically securing a first object to a second object, the method comprising the steps of: - providing said first object comprising a thermoplastic material in a solid state; - providing a second object having a substantially planar sheet with an edge; - positioning the first object relative to the second object to provide an assembly comprising the first object and the second object, in which assembly the edge is in contact with the thermoplastic material; - when the rim is in contact with the thermoplastic material, coupling mechanical vibration energy into the component until a flow portion of the thermoplastic material becomes flowable due to frictional heat generated between the rim and the thermoplastic material and flows around the rim to at least partially embed the rim within the thermoplastic material; - Stopping the mechanical vibration and allowing the thermoplastic material to resolidify, whereby the resolidified thermoplastic material at least partially embedded in the edge anchors the first object into the second object; wherein the first object comprises a body defining a functional area and at least one attachment area comprising the thermoplastic material and an attachment flange extending laterally along at least a portion of the body, and during the step of coupling mechanical vibration energy into the assembly, at least a portion of the attachment flange is clamped between an axially acting sonotrode and the second object.

21. The method according to claim 20, wherein: wherein the attachment flange is a peripheral, laterally protruding portion of the first object and / or wherein the attachment flange comprises a proximally facing marked surface portion located at a position corresponding to the attachment site.

22. A method of mechanically securing a first object to a second object, the method comprising the steps of: - providing said first object comprising a thermoplastic material in a solid state; - providing a second object having a substantially planar sheet with an edge, the sheet having a perforation, the edge extending along the perforation and the sheet having a section along the edge protruding away from the plane of the sheet; - positioning the first object relative to the second object to provide an assembly comprising the first object and the second object, in which assembly the edge is in contact with the thermoplastic material; - when the rim is in contact with the thermoplastic material, coupling mechanical vibration energy into the component until a flow portion of the thermoplastic material becomes flowable due to frictional heat generated between the rim and the thermoplastic material and flows around the rim to at least partially embed the rim within the thermoplastic material; - Stopping the mechanical vibration and allowing the thermoplastic material to resolidify, whereby the resolidified thermoplastic material at least partially embedded in the edge anchors the first object into the second object; The method comprises adjusting a position of the first object and / or of the sonotrode relative to the second object.

23. The method of claim 22, wherein the position of the sonotrode relative to the second object is defined, and the adjusting step comprises adjusting the position of the first object between and relative to the sonotrode and the second object.

24. The method of claim 23, wherein the adjusting step comprises positioning the first object using a guide tool including a spring.

25. The method of claim 22, comprising defining a position of the first object relative to the sonotrode, wherein the adjusting step comprises adjusting the position of the first object-sonic electrode assembly relative to the second object, wherein the sonotrode comprises a guide structure cooperating with a corresponding structure of the first object to define the position of the first object relative to the sonotrode, and / or wherein the step of defining the position of the first object relative to the sonotrode comprises applying a vacuum between the first object and the sonotrode, and / or wherein the step of defining the position of the first object relative to the sonotrode comprises providing a guide that is guided laterally both relative to the sonotrode and relative to the first object.

26. A method of mechanically securing a first object to a second object, the method comprising the steps of: - providing said first object comprising a thermoplastic material in a solid state; - providing a second object having a substantially planar sheet with an edge, the sheet having a perforation, the edge extending along the perforation and the sheet having a section along the edge protruding away from the plane of the sheet; - positioning the first object relative to the second object to provide an assembly comprising the first object and the second object, in which assembly the edge is in contact with the thermoplastic material; - when the rim is in contact with the thermoplastic material, coupling mechanical vibration energy into the component until a flow portion of the thermoplastic material becomes flowable due to frictional heat generated between the rim and the thermoplastic material and flows around the rim to at least partially embed the rim within the thermoplastic material; - Stopping the mechanical vibration and allowing the thermoplastic material to resolidify, whereby the resolidified thermoplastic material at least partially embedded in the edge anchors the first object into the second object; The second object includes an extension opening, and the extension portion of the first object is extended through a mouth of the extension opening at least after the stopping step.

27. The method of claim 26, further comprising providing a connector and positioning the connector relative to the first object such that the connector extends into or through the extension portion and through a mouth of the extension opening.

28. A device suitable for use in the method according to any one of claims 1-3, 5-6, 8-9, 11-27, wherein the device is the first object or the second object.

Images