Combine objects together

Abstract

The invention relates to the field of mechanical engineering and construction, in particular mechanical construction such as automotive engineering. The invention relates to a method for joining a first object (1) to a second object (2), the method comprising the following steps: providing a plurality of profile bodies (3), each profile body (3) comprising a first profile body part (3.1); providing a first object (1), the first object (1) comprising a thermoplastic material; providing a second object (2), the profile body (3) being separate from the second object (2) and attachable to the second object (2), or the second object (2) comprising the profile body (3); embedding the profile body (3) in the first object (1) such that each first profile body part (3.1) is located within the thermoplastic material of the first object (1). The embedding of the profile body (3) in the first object (1) is caused by mechanical energy applied to the first object (1) and / or the second object (2) while the first object (1) and the second object (2) are pressed against each other. The invention also relates to a profile body (3) for joining a first object (1) to a second object (2).

Description

[0001] This application is a divisional application of the Chinese invention patent application with application date of January 9, 2018, application number 201880015864.7, and invention name “Combining objects together”. Technical Field

[0002] The present invention relates to the field of mechanical engineering and construction, in particular mechanical construction such as automotive engineering. Background Art

[0003] In the automotive, aerospace and other industries, methods of joining objects together remain a challenge due to new manufacturing techniques and new materials and the constant demand for increased efficiency. For example, the materials of the objects to be joined do not weld or weld poorly, and prior art joining techniques are often time consuming (e.g., when adhesives are used) or adversely affect the structural stability of the objects to be joined, such as by introducing stress and / or weakening the objects.

[0004] WO2015 / 110311A1 discloses a method for connecting fiber-reinforced connecting elements formed of plastic material by an ultrasonic welding method. It solves the problem of low stability of the connecting position caused by the connecting position not penetrated by the fiber. According to the teaching of WO2015 / 110311A1, the problem is solved by arranging a concentrator and / or an insert element in the area of ​​the connecting surface before fusion.

[0005] Furthermore, the visual impression of the components after bonding, for example, is becoming increasingly important, since it is an indicator of good processing and high quality. However, an improvement in the visual impression should not be achieved at the expense of the reliability of the bond produced. Summary of the invention

[0006] It is an object of the present invention to provide a method for joining objects together, in particular a method for joining a first object to a second object.

[0007] In particular, the object of the invention is to overcome the disadvantages of the prior art, such as disadvantages related to materials that cannot be welded in the desired manner, poor operational stability, and stresses or negative effects on the structural stability of the object. In particular, the object of the invention is to provide a joining method and an associated profile body that allow achieving a high joining stability and a low penetration depth of the profile body into the object.

[0008] Another object of the invention is to provide a method for joining objects together in such a way that the visual impression of the surfaces visible after joining is not affected by the joining process.

[0009] In particular, an object of the present invention is to provide a method for bonding a first object to a second object in such a way that such little stress is generated that a surface of the first object or of the second object which is visible after bonding the two objects is not deformed and which does not deform during use of the bonded first and second objects.

[0010] According to the present invention, a method for bonding a first object to a second object is provided, wherein the first object and the second object may have adjacent surface portions which partially lie flat against each other and, for example, the second object has a complex surface shape. In this case, according to the prior art, adhesive bonding is used for fastening. However, adhesive bonding has certain limitations.

[0011] The present invention provides another solution. According to the invention, a plurality of profile bodies of non-liquefiable material are used as connecting elements between a first object and a second object. The profile bodies can in particular be metallic and / or can be bendable. The profile bodies can be separate components, in particular they are separable from the first object and the second object, or the second object can comprise the profile bodies. The profile bodies can be attached to the first object and / or the second object. At least the first object comprises a thermoplastic material. The method comprises embedding the profile body into the first object so that the first profile body is partially located within the thermoplastic material of the first object, wherein when the first object and the second object are pressed against each other, mechanical energy applied to the first object and / or the second object causes the profile body to be embedded in the first object.

[0012] The thermoplastic material of the first object can become flowable by absorbing mechanical energy while the objects are pressed against each other. Mechanical vibrations can be coupled into the interface with the profile body via the first object and / or the second object and can further be coupled into the interface with the second object / first object, respectively, via the profile body. At the respective interface, external friction and possibly also internal friction will cause the thermoplastic material to heat up and become flowable, so that due to the applied pressing force the profile body will be pressed into the material and thus embedded. The structure of the profile body with contours can act as an energy director, i.e. the energy absorption and heat generation will automatically be focused at the respective interface.

[0013] In particular, the profile body may be shaped as an undercut relative to the proximal-distal axis (i.e. the axis along which the first and second objects are pressed against each other, also referred to herein as the "axis"). The undercut may be formed by a structure suitable for forming a form-fitting connection with the thermoplastic material of the first object (and, as the case may be, the second object). Additionally or alternatively, the undercut may be formed by the overall shape of the profile body part to be embedded, for example by an opening of the profile body part having a diameter that varies along the embedding direction.

[0014] Therefore, the method according to the present invention comprises the following steps:

[0015] · Provide multiple profile bodies. For example, 3, 4 or more profile bodies may be provided. Each profile body includes a first profile body portion. For example, the first profile body portion may include the proximal end or the distal end of the profile body.

[0016] Providing a first object, wherein the first object comprises a thermoplastic material in a solid state. For example, the first object may comprise a thermoplastic body having a surface made of an alloy or a metal.

[0017] • Providing a second object, wherein the profile body is separate from the second object and can be attached to the second object, or wherein the second object comprises the profile body. In case the profile body is separate from the second object, the profile body can be configured to be anchored in the second object.

[0018] - Embedding the profile body in the first object such that each first profile body portion is located within the thermoplastic material of the first object.

[0019] In addition, the method includes a step of attaching the profile body to the second object in an embodiment where the profile body is separate from the second object and can be attached to the second object. For example, each profile body can include a second profile body part, and the profile body is attached to the second object via its second profile body part.

[0020] The first profile body portion and the second profile body portion do not need to be oriented along the same axis. Instead, the longitudinal axis of the first profile body portion (hereinafter also referred to as the first axis) can be offset from the longitudinal axis of the second profile body portion (hereinafter also referred to as the second axis).

[0021] The second object may include a thermoplastic material, and the profile body may be attached to the second object by embedding the profile body into the second object such that the second profile body is partially located within the thermoplastic material of the second object.

[0022] The thermoplastic material of the second object may be different from the thermoplastic material of the first object.

[0023] • Mechanical energy applied to the first object and / or the second object causes embedding of the profile body in the first object (and, as the case may be, the second object) when pressed against each other on the first object and / or the second object.

[0024] The pressing step is performed until adjoining surface portions of the first object and the second object abut against each other, wherein the profile body is embedded in the material of the first object and attached to the second object.

[0025] One insight of the invention is that the method allows a first object to be bonded to a second object even when the first object and the second object as a whole or at their bonding location are made of materials with widely varying properties. In particular, their properties may vary such that welding and / or the use of adhesives is not possible or results in a bonding with insufficient mechanical stability.

[0026] A further insight of the invention is that the method allows the first object to be joined to the second object with a low penetration depth into the first object and / or the second object, for example in cases where the properties of the materials of the first object and the second object vary widely. This is important since any penetration of the connecting element can adversely affect the stability of the objects and said effect depends on the penetration depth.

[0027] For example, the first object may be a composite material comprising a thermoplastic material, such as a laminate or a fiber-reinforced composite material. However, the first object may also be a foil.

[0028] The second object may be a composite material. For example, it may be a laminate, a fiber reinforced composite material or a hollow core panel.

[0029] At least one profile body, in particular each profile body, may comprise a plurality of first profile body portions. In other words, each profile body may comprise a plurality of locations which embed and bond the profile body to the first object.

[0030] In addition, each profile body may include one or more than one (i.e., multiple) second profile body parts. In other words, each profile body may include multiple locations, where the first object is attached to the second object, for example, by embedding the second profile body part in the second object.

[0031] The first profile body part(s) and the second profile body part(s), if any, may be designed to affect the stability of the first object (and, where appropriate, the second object) as little as possible. In particular, the first profile body part(s) may have a length along the first axis which is less than 5 mm, in particular less than 3 mm or 2 mm. For example, the length may be between 0.1 mm and 2 mm, for example about 0.8 mm, 1 mm, 1.2 mm, 1.4 mm, 1.5 mm, 1.6 mm or 1.8 mm.

[0032] A further insight of the present invention is that a reliable bond between the first object and the second object can be achieved, in particular a reliable bond relative to a tensile force applied to the first object and / or the second object, which produces a significant force component along the axis of the profile body, wherein the length along the first axis is between 0.2 mm and 0.5 mm.

[0033] In an embodiment comprising a profile body portion formed by an undercut by an opening and a cavity having a diameter that increases along the embedding direction, wherein its smallest diameter is the diameter of the opening, the resistance to the tensile force depends firstly on the smallest diameter, the largest diameter (e.g. the diameter of the cavity bottom) and the design of the cavity, which means the way in which the cavity transforms from the smallest diameter to the largest diameter. Details on the relationship between bonding reliability and design are given in WO 2017 / 055548 A1, in particular in Figure 1 b, Figure 46, Figure 47 and the corresponding description. WO2017 / 055548A1 is incorporated herein by reference.

[0034] Generally, an increase in the minimum diameter is beneficial in terms of resisting tensile forces.

[0035] It has been found that a design of the profile body part having a ratio between length (height) and minimum diameter which is less than 1, in particular between 0.1 and 0.5, yields good results in terms of bonding reliability.

[0036] It is conceivable to increase the length (height) of the main part of the profile in order to increase the reliability of the bond against shear forces.

[0037] However, good overall reliability has been observed with profile body portions having a length (height) between 0.3 and 2 mm and a minimum diameter between 1 and 10 mm, in particular with a length between 0.5 mm and 1 mm and a minimum diameter between 2 mm and 3 mm.

[0038] Each profile body may comprise a base element from which the first profile body portion(s) (and optionally the second profile body portion(s)) protrude.

[0039] In particular, the element forming the support surface as discussed in detail later is a base element.

[0040] The base element may form at least one support surface.

[0041] The profile body may comprise a support surface which is not formed by a base element.

[0042] For example, the base element may have the shape of a plate which is adapted to the shape of the first body surface portion in which the profile body is embedded and the second body surface portion to which the profile body is attached.

[0043] If the profile body is made of sheet metal, the profile body part can be formed by deforming the sheet metal. In particular, the undeformed part of the sheet metal can form the base element. For example, the profile main part can be formed by punching (stamping) the sheet metal.

[0044] In an embodiment, the base element is a plate, which may be planar or non-planar and has a first surface and a second surface, wherein the first profile body portion(s) protrude from the first surface and the second profile body portion(s) protrude from the second surface. The second surface may be opposite to the first surface.

[0045] For example, the first profile body part(s) and the second profile body part(s) may be arranged in pairs on the base element, such that a pair of the first body part and the second body part are arranged at the same position, but on opposite sides of the base plate. Alternatively, the position(s) of the first profile body part(s) on the first surface of the base element deviate from the position(s) of the second profile body part(s) on the second surface of the base element. Such an arrangement of the first profile body part and the second profile body part is advantageous in terms of the manufacture of the profile body. The profile body having such an arrangement of the profile body parts can be manufactured by punching (stamping) the base element.

[0046] In one embodiment, the method comprises the further step of providing an adhesive.

[0047] One insight of the invention is that a bonding method involving embedding of a profile body is particularly advantageous for materials of a first object and a second object which need or are intended to be bonded to each other by means of an adhesive. Adhesive bonding methods generally have such poor stability at the beginning of the bonding process that the objects need to be left to rest for a period of time or the objects need to be provided with undesirable shape features in order to mechanically block the relative movement of the objects to be bonded.

[0048] It has been found that the method according to the invention leads to a reduction in the time that the bonded objects need to rest when using an adhesive. In other words, the method according to the invention leads at least to a reduction in the time to achieve process stability.

[0049] At least one of the shapes of the first object, the second object and the profile body may be such that during the method an adhesive gap, that means a space for adhesive, is produced between a surface portion of the first object and a surface portion of the second object.

[0050] Thus, the step of providing an adhesive may include the sub-step of providing an adhesive gap.

[0051] The adhesive gap can be produced during the method passively by means of spacer elements and / or actively by means of distance control.

[0052] For example, the first object may include a first object recess arranged on the same side of the first object as the first object surface portion, and / or the second object may include a second object recess arranged on the same side of the second object as the second object surface portion.

[0053] Alternatively or additionally, the base element may have such a thickness that the first object and the second object do not abut after bonding but are separated by an adhesive gap. In particular, the first object and the second object do not abut in a region adjacent to the profile body.

[0054] For example, the thickness of the base element may be less than 5 mm, in particular less than 3 mm or 2 mm. In particular, the thickness is about 1 mm and 1.5 mm. In applications where, for example, no adhesive gap is required, the thickness may be lower than 1 mm, for example 0.3 mm or 0.5 mm. The thickness may be given by the thickness of the metal sheet forming the base element.

[0055] Alternatively or additionally, the adhesive gap may be formed by applying a predetermined pressure during the embedding step and by designing the profile body and optionally the adhesive so that during the method a resistance against closing the gap between the first object and the second object is generated, the resistance increasing as the gap decreases. Alternatively, the profile body may be designed so that the resistance increases stepwise at a given gap (distance) between the first object and the second object. For example, the profile body may include a support surface, as described later.

[0056] In various embodiments, the first object, the second object and / or the profile body are designed such that the adhesive gap is between 0.1 mm and 2 cm, in particular between 0.2 mm and 0.5 cm, for example between 0.2 and 2 mm.

[0057] In an embodiment, the method comprises the step of establishing a seal.

[0058] The step of establishing a seal may comprise providing a sealing element, such as a sealing strip or a sealing ring, and positioning the sealing element relative to the first object, the second object and the profile body. In particular, the sealing element is positioned before the step of embedding the profile body.

[0059] The step of establishing a seal may include providing a first object including an elastomeric portion, which is arranged on the same side of the first object as the surface portion of the first object and protrudes from it, or providing a second object including an elastomeric portion, which is arranged on the same side of the second object as the surface portion of the second object and protrudes from it.

[0060] In particular, the elastomeric portion is arranged such that it is compressed between the first object and the second object during the method.

[0061] The step of establishing a seal may be an additional step to providing the adhesive and related sub-steps.

[0062] A sealing element or elastomeric portion may help to form the adhesive gap.

[0063] It has been found that the method according to the invention can be used to establish a sealed bond of a first object to a second object without increasing the processing time and / or complicating the bonding process. This is because the profile body fixes the position of the first object relative to the second object shortly after the application of the mechanical energy that causes the thermoplastic material to become flowable. Bonding methods based on adhesives and welds cannot support the required compressive forces before the adhesive or weld hardens. In contrast to these methods, the method according to the invention provides a relative fixation that can support said compressive forces shortly after assembling the first and second objects.

[0064] Embodiments of the method can be distinguished by the profile bodies provided. The profile bodies can differ in any of the disclosed features. In particular, their elastic deformability, the mechanism for determining the maximum penetration depth and / or the generation of the adhesive gap can differ.

[0065] In particular, the profile body is designed such that each first profile body portion is embedded in an area of ​​the first object which is designed to be smaller than an area of ​​the first object facing the second object during bonding. In other words, the profile body is designed to form a small area.

[0066] Examples of profile bodies designed in this way are described below. In particular, profile bodies can be used which include at least one first profile body part having a cross section perpendicular to the embedding direction to form, for example, a closed loop or an open ring including at least two ends bent toward each other, such as an open ring or a spiral. Such profile bodies are particularly advantageous if they are constructed in such a way that the embedding of the profile body is provided at a first opening. The first opening can be an opening into a cavity formed by the profile body.

[0067] In many embodiments, the first opening is the proximal end or the distal end of the profile body, depending on the relative arrangement (particularly the stacking order) and orientation of the first object, the second object and the profile body.

[0068] If the profile body comprises at least one second profile body part which is attached to or embedded in a second object, the above may apply to each second profile body part.

[0069] A design of the profile body which results in the first profile body part being embedded in a small, i.e. positioned area of ​​the first object and, as the case may be, the second profile body part being attached or embedded in a small, i.e. located area of ​​the second object rather than being embedded in a large, i.e. extended and / or non-located area of ​​the first object and, as the case may be, the second object. "Large" also means that the area extends over a significant area of ​​the surface of the first (second) object facing the second (first) object during bonding.

[0070] Another advantage of a small range of bonding locations is that the bonding locations can be arranged in a manner that is optimized for the shapes of the first object and the second object.

[0071] Another advantage is that the joining locations can be optimized with respect to the stresses induced in the first and ultimately the second body, in particular during joining. Furthermore, the overall stresses induced by small-scale joining locations are less than those induced by extended joining locations. Finally, it is often advantageous to combine small-scale joining locations with measures for further stress reduction, such as stress relief structures, reservoirs, compensation areas and / or elastic deformability described below.

[0072] In particular, the method according to the invention comprises at least the following construction between the profile body, the first object and the second object:

[0073] The initially provided profile bodies are separated from each other and from the second (and first) object.

[0074] The profile body consists of a second object, wherein the second object may be made of or include a thermoplastic material, or wherein the second object does not include any thermoplastic material. For example, the second object may be made of an alloy, a metal or a composite material. However, the second object may include a thermoplastic body having a surface made of an alloy or a metal.

[0075] At least one of the first object and the second object may include a surface that is visible after joining the first object and the second object, such as a so-called A-surface.

[0076] In an embodiment of the method, the provided profile bodies are separate profile bodies apart from a possible connection by the second object.However, the provided profile bodies may be completely separate, ie separate from each other and from the first object and the second object.

[0077] In particular, the initially provided profile body neither forms nor is part of another continuous object besides the second object.

[0078] In particular, typically in embodiments, the profile body may be a different material than the second object. For example, the profile body may be metal or a relatively hard plastic, and the second object may include, at least in the region of the surface portion that is in contact with the first object (hereinafter "second object surface portion"), a thermoplastic material. In embodiments where the profile body is of a different material than the second object, the assembly of the second object with the profile body does not include joining any portion of the profile body material to the profile body.

[0079] In an embodiment, the second object has a substantially planar second object surface portion, the first profile body portion protruding from the second object surface portion, in particular the first profile body portion undercuts relative to an axis which is generally perpendicular to the second object surface portion.

[0080] In another embodiment of the method, the step of providing the second object comprises providing the second object with a profile body comprising: In particular, the profile body is integral with the second object.

[0081] In the embodiment where the second object comprises a profile body, the second object may be manufactured by injection molding, for example, the second object is placed in a mold and the rest of the second object is injection molded around the second profile body portion.

[0082] However, it is also possible to process the second object before the step of providing the second object such that it comprises a profile body.

[0083] As described above, an object of the present invention is to provide a method for bonding a first object to a second object in such a manner that such little stress is induced that the surface of the first object or the second object visible after bonding the two objects is not deformed, and it is not deformed during use of the bonded first and second objects.

[0084] One insight of the invention is that the use of a plurality of profile bodies which are not connected to one another or are connected only at the beginning of the bonding via the first or second body and only after the bonding via the first or second body significantly reduces the stresses induced in the objects during and after the bonding. This is a surprising finding, since the bonding only takes place very locally. In particular, for example, an increase in stress at the bonding location over a small area can be expected and thus a negative impact on nearby surfaces.

[0085] After the bonding, stresses in the first body and / or the second body are caused, for example, by external influences, such as changes in temperature and / or changes in humidity.

[0086] Furthermore, the use of multiple profile bodies paves the way for further stress reduction. Further stress reduction can be achieved by at least one of the following:

[0087] The profile body is configured to deform elastically in response to a tension force generated by a movement of the first object relative to the second object. The movement may be, for example, different external influences on the first object and the second object and / or the result of these influences. The result may depend on the properties of the material forming the first object or the material forming the second object.

[0088] In particular, the profile body is configured to be elastically deformable in a direction parallel to the first and second object surface portions abutting against each other, i.e. in a direction perpendicular to the (longitudinal) axis of the profile body. In addition, the profile body can be shaped to be rigid, i.e. not deformable by any forces acting in the axial direction. In other words, the profile body can be shaped such that the mechanical resistance to in-plane deformation is substantially lower (e.g. by at least one order of magnitude) than the mechanical resistance to axial deformation.

[0089] For example, the profile body may have an open shape in a cross section perpendicular to the axis (perpendicular to the first and second body surface portions abutting against each other). An open circular or spiral shape in a cross section perpendicular to the axis is an example of such an open shape.

[0090] However, the profile body may also have a wave shape in a cross section perpendicular to an axis perpendicular to the first and second body surface portions abutting against each other, or the axis may be the axis of rotation of each profile body. In particular, the profile body may be symmetrical under a rotation of 120 degrees or 90 degrees.

[0091] In addition or as an alternative to the elastic deformability of the profile body given by its shape, the profile body may be hollow, for example by comprising an opening extending along an axis perpendicular to the first and second object surface portions abutting against each other. The thickness of the walls of the hollow profile body may be such that the walls do not hinder the deformation of the profile body when said tensile force is applied. In particular, the profile body may be made of sheet metal.

[0092] The first object and / or the second object comprises a stress relief structure, wherein the stress relief structure is provided for reducing stress inside the object comprising the stress relief structure. In particular, the stress relief structure may be a structure configured to compensate for different expansions in a plane perpendicular to the axis. For example, the stress relief structure may be a part of the second object or the first object, respectively, whose in-plane dimensions may be adapted by applying a relatively small in-plane force.

[0093] For example, the stress relief structure may be an area of ​​the object that is thinner than other areas of the object (along an axis perpendicular to the surface portion of the object that is opposite the other object when the first object and the second object are combined). Other areas of the object may include areas where the profile body is embedded or attached. In other words, the location of the stress relief structure may be different from the location of the profile body.

[0094] Additionally or alternatively, the stress relief structure may be shaped to facilitate stress relief. For example, the stress relief structure may be part of a corrugated or narrowed object.

[0095] A reservoir in or formed by at least one of the first and second objects. For example, the reservoir may be formed by a recess or notch on one side of the object that is joined to the other object.

[0096] The reservoir is arranged such that thermoplastic material displaced during the step of embedding the profile body in the first object or during the step of embedding the profile body in the first object and in the second object is accommodated in the reservoir.

[0097] In particular, the reservoir is arranged such that it comprises or at least surrounds a portion of the profile body.

[0098] In most embodiments, the number of reservoirs is adapted to the number of profile bodies.

[0099] Such a reservoir has the effect that the thermoplastic material displaced during embedding, in particular the thermoplastic material which has not liquefied, is placed between the surface portions of the first and second objects which are in contact with each other. As a result, no indentations which could be caused by such displacement are produced. In other words, the stresses induced in the first and second objects during bonding are significantly smaller.

[0100] In embodiments comprising at least one reservoir, the method may comprise the further step of positioning the profile body relative to each reservoir such that thermoplastic material displaced during embedding may enter the reservoir(s).

[0101] • At least one of the first objects may include a first surface opening in a surface portion of the first object, and the second object may include a second surface opening in a surface portion of the second object.

[0102] The first surface opening or the second surface opening or the first surface opening and the second surface opening are designed to accommodate a part of the profile body which is different from the profile body part(s), in particular the base element.

[0103] The surface opening(s) have the effect that parts of the profile body that are different from parts of the profile body(s) do not induce stresses in the first object and / or the second object during and after the joining. Instead, the first object and the second object can be joined in a gap-free manner. This means that after joining the first object and the second object, the surface parts of the first object are in direct contact with the surface parts of the second object. Thus, any mechanical energy and pressure applied to the first object and / or the second object after embedding the profile body is distributed over the adjacent surface parts of the first object and the second object.

[0104] The reservoir may be part of a surface opening.

[0105] The surface opening(s) may be designed such that it / they take over the function of a recess. In particular, the surface opening may have a depth, or the surface openings may have a cumulative depth, which is greater than the maximum thickness of the portion of the profile body to be accommodated in the surface opening(s), which means that this portion of the profile body is different from the profile body portion(s).

[0106] In an embodiment, the reservoir is combined with a surface opening.

[0107] A compensation area in at least one of the first object and the second object, which is arranged so that a portion of the profile body embedded in the first object and attached to the second object can be deformed without coming into contact with the material of the first object and the second object and without coming into contact with the material of the first object and the second object. In particular, the compensation area forms an open space around said portion of the profile body.

[0108] The open space defines a free path length of the profile body which, in combination with the deformation properties of the profile body, defines a maximum possible movement of the first object relative to the second object in a direction perpendicular to the axis of the profile body (parallel to the surface portions of the first and second objects).

[0109] For example, the profile body may be such that it can be elastically deformed in a direction perpendicular to its axis by 1%, 2%, 3% or 5% of the free path length.

[0110] In particular, as described above, the profile body can be configured such that it is rigid along its axis, ie elastically non-deformable, and elastically deformable in a direction perpendicular to its axis.

[0111] In most embodiments, the number of compensation regions is adapted to the number of profile bodies.

[0112] In an embodiment comprising at least one compensation region, the method may comprise an additional step of positioning the profile body relative to each compensation region such that the compensation region forms a gap around a portion of the profile body after embedding the profile body into a first object or after embedding the profile body into a first object and attaching the profile body to a second object.

[0113] Such a compensation region has the effect that the first object and the second object can slide against each other while being coupled to each other in a direction perpendicular to the surface portion of the first object and the surface portion of the second object abutting against each other, while generating minimal stress in the first object and the second object. Thus, the compensation region is suitable for deformation and movement of the first object and the second object along an axis parallel to the surface portion of the first object and the surface portion of the second object abutting against each other.

[0114] In particular, the compensation region is adapted to compensate for differences in elasticity and / or thermal expansion coefficients of the material forming the first object and the material forming the second object and / or to compensate for differences resulting from different exposure of the first object and the second object to temperature fluctuations.

[0115] Any embodiment of the method may include at least one further measure for reducing stresses, for example in addition to the use of a plurality of profile bodies as described above.

[0116] In an embodiment, during the step of embedding the profile body into the first object, a plurality of profile bodies are embedded into the first object simultaneously. In other words, the mechanical energy and pressure applied to the first object and / or the second object expose all the profile bodies to mechanical energy and pressure sufficient to embed the profile bodies.

[0117] For example, the simultaneous embedding of the profile body into the first object can be accomplished by a sonotrode comprising a distal coupling surface which is adapted to the position of the profile body.

[0118] The present invention also relates to a profile body for joining a first object to a second object, in particular a profile body for joining a first object to a second object by performing the method in any embodiment.

[0119] In a first group of embodiments of the profile body, the profile body comprises an axis and a first profile body portion, and a first opening, the first profile body portion having a structure suitable for forming a form-fitting connection, in particular when embedded in a first object. The profile body is further configured to elastically deform in response to a force applied from a direction perpendicular to its axis.

[0120] In particular, the profile body is equipped to deform elastically along an axis perpendicular to its axis.

[0121] In a second group of embodiments of the profile body, the profile body comprises an axis and a first profile body part and a first opening, the first profile body part having a structure suitable for forming a form-fitting connection, in particular when embedded in a first object. The profile body further comprises a support surface, which is arranged to determine a maximum penetration depth of the profile body, in particular the first profile body part, in the first object.

[0122] Embodiments of the first group may include a support surface.

[0123] The second group of embodiments can be configured to elastically deform in response to a force applied from a direction perpendicular to its axis. In particular, they can be configured to elastically deform along an axis perpendicular to its axis.

[0124] The profile body according to the first or second group may include one or more of the following features:

[0125] The profile body may have a substantially cylindrical shape. In particular, the profile body may be sleeve-shaped.

[0126] The profile body may form a cavity, in particular a cavity accessible from the first opening.

[0127] The profile body may be made of or contain a metal or a polymer which is not liquefiable or which is liquefiable only at a much higher temperature than the material of both the first and the second object.

[0128] The profile body may have a shape in a cross section perpendicular to its axis (i.e. in a plane parallel to the first object surface portion and the second object surface portion after embedding) which corresponds to at least one of a closed loop (e.g. in the case of a profile body having a cylindrical shape), an open loop (e.g. a split ring) comprising at least two ends bent towards each other, a split ring comprising at least two ends not bent towards each other. Examples of the latter are shapes comprising or consisting of (multiple) substantially straight portions, (multiple) corrugated portions, (multiple) curved portions and / or (multiple) bent portions in the cross section.

[0129] The profile body may have at least one of a substantially straight, stepped, bent and curvilinear form in a cross section parallel to its axis (i.e. in a plane perpendicular to the first and second object surface portions after embedding). In particular, the form may be a supplement to the support surface, which in an embodiment corresponds to a portion extending perpendicularly to the axis of the profile body.

[0130] The profile body can be made of sheet metal.

[0131] The profile body may be a folded metal sheet with an opening pattern or a metal sheet with a plurality of partially cut-out and folded portions (tongues), etc.

[0132] The profile body may have a second profile body part and a second opening, the second profile body part having further structures adapted to form a form-fitting connection, in particular when embedded in a second object.

[0133] • The profile body may comprise a base element.

[0134] The first profile body portion may protrude from the base element such that, when the first profile body portion is embedded in the first object, the base element extends substantially parallel to a surface portion of the first object.

[0135] Furthermore, the profile body may comprise a second profile body portion.

[0136] The second profile body part may protrude from the base element such that the second profile body part may be attached to the second object when the first profile body part is embedded in the first object.

[0137] In an embodiment of the profile body comprising a base element, the profile body may comprise at least three profile body parts, for example a plurality of first profile body parts (which means that the profile body part arranged on the base element is embedded in the first object) and a plurality of second profile body parts (which means that the profile body part arranged on the base element is embedded in the second object).

[0138] In any embodiments comprising a base element, the base element may include a stress relief structure and / or a reservoir in any of the embodiments described above with respect to the first object and / or the second object.

[0139] Both the first profile body portion and the second profile body portion may be arranged along the axis. However, the first profile body portion and the second profile body portion may be arranged at an angle relative to each other. In particular, at a right angle.

[0140] The axis of the profile body according to the first and / or second embodiment of the profile body may be a first axis, wherein the first axis is the axis of the first profile body part.

[0141] The profile body may comprise a second profile body portion and a second axis, wherein the second axis is the axis of the second profile body portion.

[0142] Embodiments of the profile body can be distinguished by the relative orientation of the first axis and the second axis.

[0143] For example, the first axis and the second axis may extend perpendicularly to the plane defined by the base element and be offset from each other. In other words, the first axis and the second axis do not coincide but are parallel to each other. In particular, the first profile body portion and the second profile body portion may be arranged on opposite sides of the plane.

[0144] However, embodiments are also conceivable in which the first axis extends at an angle to the second axis. This is the case in particular when the portion of the first object surface in which the first profile body is embedded is parallel or non-parallel to the portion of the second object surface to which the second profile body is attached.

[0145] The structure of the first profile body part and / or the second profile body part suitable for forming a form-fitting connection may be at least one of an undercut, a hole and a twist.

[0146] In an embodiment, the profile body has an aspect ratio, ie a ratio between its extension in the axial direction and its extension in the radial direction relative to its axis, of less than two, in particular less than one.

[0147] In an embodiment of the method, the profile body provided is dimensioned such that when embedded in the first object the profile body extends in the first object to at least a first depth that is less than the thickness of the first object, and such that when attached to the second object the profile body extends in the second object to at least a second depth that is less than the thickness of the second object. The thickness of the first object and the thickness of the second object are the respective extensions of the objects along a direction perpendicular to the surface of the object which bears against the other object after bonding.

[0148] In particular, after the bonding, at least one surface of the first object or the second object is not penetrated by any profile body. The A surface is one of the at least one surface.

[0149] The profile body has a contour which defines a structure suitable for forming a positive connection with the thermoplastic material of the first object.

[0150] The contour of the profile body may comprise additional structures which are suitable for forming a positive connection with the material of the second object.

[0151] In an embodiment comprising a profile body having a contour defining said structure, the step of embedding the profile body in the first object comprises embedding the structure, which is arranged to form a form-fitting connection in the thermoplastic material of the first object.

[0152] In an embodiment comprising a profile body having a contour defining the further structure, the method may comprise a step of attaching the profile body to the second object by forming a form-fitting connection with the second object. The attaching step may embed the further structure, which is configured to form a form-fitting connection in the thermoplastic material of the second object. However, the attaching step may also comprise producing a form-fitting connection by engaging the further structure with a corresponding structure of the second object.

[0153] The structure suitable for forming a positive connection and the additional structure suitable for forming a positive connection can be in particular a structure undercut relative to the axial direction. Examples thereof include at least one radially extending protrusion or recess, a twist, a hole, etc.

[0154] In particular in both embodiments the first profile body and the second profile body are each undercut with respect to the axial direction, whereby after this process the profile bodies are fixed to the first and the second object by a form-fitting connection.

[0155] In an embodiment, the contour-defining undercut of the profile body consists of a portion of a suitably folded, deformed metal sheet, or may consist of a cast body (eg die-cast) or the like.

[0156] This structure suitable for forming a form-fitting connection and this further structure, which is optionally interpenetrated by materials of the first material / second material, are fixed after resolidification so as to prevent the first object / second object from being pulled apart (in an out-of-plane direction relative to the surface portion around the position where each profile body is embedded; this out-of-plane axis is also referred to as the "proximal-distal axis" in this document).

[0157] In one set of embodiments the second body also comprises thermoplastic material.

[0158] In this set of embodiments, the profile body is initially separated from the second object and attached to the second object by a method comprising the further step of embedding the profile body in the second object such that the second profile body is partially located within the thermoplastic material of the second object.

[0159] The profile body may have an additional structure which is suitable for a positive connection with the thermoplastic material of the second body, which is identical to one of the possible structures which is suitable for a positive connection with the thermoplastic material of the first body.

[0160] When the first object and the second object are pressed against each other, the mechanical energy applied to the first object and / or the second object causes embedding of the profile body in the second object.

[0161] The step of embedding the profile body in the second object can be done during the step of embedding the profile body in the first object, ie simultaneously or in separate steps, for example sequentially, one after the other.

[0162] In a subset of embodiments in which the second object also comprises a thermoplastic material, the method is performed such that the first profile body and the second profile body portion are embedded in the thermoplastic material of the two objects substantially simultaneously, i.e. by an energetic action that causes the thermoplastic material portions of the two objects to become flowable at the same stage. To this end, the material composition and / or the shape of the profile body portion of the first and second objects may differ slightly in order to compensate for the fact that, without such measures, the energy absorption may be higher at the interface between the profile body portion and one of the objects into which the mechanical vibrations can be coupled.

[0163] In the subset of embodiments in which the second object also comprises thermoplastic material, at least one of the profile body, the first object and the second object may be designed such that the first profile body portion and the second profile body portion are embedded in the thermoplastic material of the object substantially simultaneously or sequentially.

[0164] The embedding time of the profile body part depends on the melting properties of the thermoplastic material and the energy density coupled into the thermoplastic material. If energy causing liquefaction of the thermoplastic material is applied to the first object or the second object, it is necessary to take into account that the applied energy is damped not only by the object to which it is applied but also by the profile body, if the embedding involves a profile body part which is arranged on the far side of the profile body with respect to the object to which the energy is applied. Thus, embedding a first profile body part in the thermoplastic material of the first object and embedding a second profile body part in the thermoplastic material of the second object is sequential, if the thermoplastic materials are identical and the first profile body part is identical to the second profile body part.

[0165] By providing the first profile body part with a first area and the second profile body part with a second area, the embedding time of the second profile body part relative to the embedding time of the first profile body part can be adjusted, wherein the first area is designed in such a way that the first profile body part and / or the profile body are in contact with the thermoplastic material of the first object only via the first area, wherein the second area is designed in such a way that the second profile body part and / or the profile body are in contact with the thermoplastic material of the second object only via the second area, and wherein the first area is smaller or larger than the second area.

[0166] In other words, the first profile body part may comprise a first area and the second profile body part may comprise a second area, wherein the first area has a different size than the second area.

[0167] In an embodiment, the profile body portion arranged distally of the profile body relative to the object to which energy is applied may include an area designed so that the distal profile body head contacts the thermoplastic material of the distal object only through said area, said area being smaller than the corresponding area of ​​the proximally arranged profile body portion. This may enable the distal profile body head to be embedded simultaneously with or even earlier than the embedding of the proximal profile body head.

[0168] Alternatively or additionally, the embedding time of the second profile body part relative to the embedding time of the first profile body part can be adjusted by the thermoplastic material of the first body differing in melting properties from the thermoplastic material of the second body.

[0169] As an alternative or in addition to different areas of thermoplastic material having different sizes and / or melting characteristics, at least one of the profile body, the first object and the second object may include an energy director, which means a change in shape that defines a point where liquefaction enters by generating a high energy density in the energy director and / or in the material in contact with the energy director.

[0170] As an alternative or in addition to at least one area of ​​different size, a thermoplastic material with different melting characteristics, and an energy director, the profile body is capable of changing at least one of its transmission characteristics, damping characteristics, coupling characteristics and resistance to embedding during the step of embedding the profile body and / or when exposed to mechanical energy such as vibration (particularly ultrasonic) energy and / or pressure.

[0171] The profile body that changes its transmission and / or damping properties may include regions that collapse when exposed to mechanical energy of a predetermined characteristic and / or a pressure exceeding a predetermined value.

[0172] Examples of a profile body whose coupling properties can be changed during the step of embedding the profile body include a coupling surface that is in contact with an object to which energy is applied during embedding.

[0173] In particular, the coupling surface does not cause any liquefaction, but it results in an increased coupling of energy from the object to which it is applied into the profile body. Support surfaces and base elements are examples of such surfaces. The provided profile body may comprise a coupling surface.

[0174] An example of a profile body capable of changing its resistance to embedding during the step of embedding the profile body comprises a resistance surface that is in contact with an object to which energy is applied during embedding or an object to which no energy is applied during embedding.

[0175] In particular, the resistance surface changes the energy density or pressure distribution at the interface between the profile body and the object. It can soften the thermoplastic material in contact with the resistance surface. The thermoplastic surface in contact with the resistance surface can make a change in the coupling characteristics, in particular an increase in the energy coupled into the profile body possible.

[0176] The effects of at least two features "areas of different size", "energy director", "different thermoplastic material", "changing transmission properties", "changing damping properties", "changing coupling properties" and / or "changing resistance to embedding" can be used cumulatively. However, one or more features can also be used to compensate for opposite effects caused by one or more other features. For example, a greater difference in area size can be used to compensate for a mandatory arrangement of the thermoplastic material, for example given by the application, and vice versa.

[0177] Additionally or alternatively, the profile body may be designed to prevent increased embedding in one object at the expense of reduced embedding in the other object. For example, the profile body may include a support surface that extends parallel to the first and second object surfaces and creates additional resistance to embedding of the profile body once the first or second object surface contacts the support surface.

[0178] In a further subset of embodiments, in which both the first object and the second object comprise thermoplastic material, the method comprises embedding the profile body in the material of the first object before positioning the first object relative to the second object. To this end, mechanical energy, in particular vibration energy, can be applied directly to the profile body, for example, in order to embed the profile body in the first object. This is done in such a way that each second profile body portion protrudes from the first object, i.e. is not embedded in the first object. Thereafter, after the thermoplastic material of the first object has resolidified, the second object is brought into contact with the profile body and pressed towards the first object, while applying mechanical vibration energy, for example, to the second object.

[0179] In a further subset of embodiments, both the first and second objects comprise thermoplastic material, and the method may comprise welding between the first and second objects. In particular, the mechanical energy applied to the first object / second object may be sufficient to cause the thermoplastic material portion to flow also at the interface between the first object and the second object, for example close to the profile body or in a through opening thereof. For welding, the first object and / or the second object may comprise an energy directing structure, which energy directing structure comes into contact with the other object when the objects are pressed against each other to embed into the profile body.

[0180] In embodiments in which the second object also comprises a thermoplastic material, a separate profile body may be positioned between the initially separated first and second objects. The second object may then be embedded in the same step as the embedding of the first object, i.e. by applying mechanical vibrations and pressure, or in another step comprising applying pressure and mechanical vibrations. Further steps may be before or after the step of embedding the profile body in the first object. The pressure and / or mechanical vibrations applied in the further step may be different from the pressure and / or mechanical vibrations applied in the step of embedding the profile body in the first object. In particular, the pressure and mechanical vibrations applied in the step of embedding the first object may be adapted to the thermoplastic material of the first object and / or the shape of the first profile body portion. Additionally or alternatively, the pressure and mechanical vibrations applied in the further step may be adapted to the thermoplastic material of the second object and / or the shape of the second profile body portion.

[0181] Thus, in embodiments where the second object also comprises a thermoplastic material, a method of bonding a first object to a second object (wherein the first object and the second object each comprise a solid thermoplastic material and each object has a surface portion) may comprise:

[0182] providing a first object and a second object and further providing a plurality of profile bodies,

[0183] arranging the profile body relative to the first object and the second object between surface portions of the first object and the second object, wherein the profile body comprises a first profile body portion directed towards the first object and a second profile body portion directed towards the second object,

[0184] coupling pressure and mechanical vibration energy into at least one of the first object and the second object, wherein the pressure causes the profile body to be sandwiched between the first object and the second object until flow portions of the thermoplastic material of the first object and the second object become flowable, until the profile body is embedded in the first object such that each first profile body portion is located within the thermoplastic material of the first object, and until the profile body is embedded in the second object such that each second profile body portion is located within the thermoplastic material of the second object, and

[0185] Allow the thermoplastic material to resolidify.

[0186] For example (and this is an option for all embodiments), the step of coupling pressure and mechanical vibrations into the first object / second object may be accomplished by a sonotrode pressed against the respective object, while the other object may be held directly or indirectly by a support (the support may be directly against the second object at a transverse position to which the sonotrode acts, or may consist of a frame of a more complex object holding the second object; such a complex frame may be, for example, the body of the item to be assembled, such as a car body). Optionally, a protective pad may be placed between the sonotrode and the respective object, for example to avoid that the sonotrode creates an indentation on the respective object.

[0187] The distal side of the sonotrode, in particular the distal side in contact with the corresponding object or the protective pad, can include a shape adapted to the position of the corresponding object and / or the profile body. For example, the proximal side can be annular, including an opening for a portion of the corresponding object protruding away from the bonding area.

[0188] In a subset of embodiments, wherein the second object also comprises a thermoplastic material, the at least one profile body comprises a proximal profile body head and a distal profile body head.

[0189] In this subset of embodiments, the method comprises the following steps:

[0190] Positioning the distal profile body head relative to the proximal surface of the second object, in particular making the distal profile body head contact the proximal surface of the second object at a location where the first object and the second object are embedded.

[0191] Pushing the distal profile body head through the second object into the thermoplastic material of the first object until the profile body head is flush with the proximal surface of the second object.

[0192] Applications of the method according to the invention are for example in the automotive or aerospace industry or other industries where lightweight materials are a concern. In embodiments where a first object is joined to a second object, the second object may for example be a part of a car body, and wherein the first object may be a specific car part to be joined to the car body.

[0193] For example, the first object may be a part of a car body comprising an outer surface of the car, wherein the second object comprises a sensor, such as a parking sensor, which has to be engaged from the rear side of the outer surface near said outer surface.

[0194] The liquefaction of the flow portion may be caused primarily by friction between the vibrating object and the surface of the respective other object, which friction causes at least frictional heating of the object having the thermoplastic material on the surface.

[0195] In the present text, the expression "thermoplastic material capable of becoming flowable, for example by mechanical vibrations" or simply "liquefiable thermoplastic material" or "liquefiable material" or "thermoplastic" is used to describe a material comprising at least one thermoplastic component, which becomes liquid (flowable) when heated (especially when heated by friction), i.e. when arranged on one of a pair of surfaces (contact surfaces) that are in contact and move in vibration relative to each other, wherein the vibration frequency has the properties discussed above. In certain cases, for example if the first object itself has to carry a large load, it is advantageous if the material has an elastic modulus 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 during processing. In particular, since the profile body has a relatively small extension in the proximal-distal direction, the method is also suitable for fixing a relatively thin first or second object to a second or first object (including the possibility that both objects are thin), and the method of the invention also works on thermoplastic materials that are poor vibration conductors, such as thermoplastic materials with a low elastic modulus and / or with elastomeric properties. Particularly in this case, the shape of the profile body ensures that the contact with the counterpart is essentially linear. This has a high energy concentration effect and makes local liquefaction possible even if the thermoplastic material has strong damping properties.

[0196] Thermoplastic materials are well known in the automotive and aerospace industries. For the purpose of the method according to the invention, in particular thermoplastic materials known for use in these industries can be used.

[0197] 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 polymer phase (especially based on C, P, S or Si chains) which is converted from a solid state to a liquid state or flowable above a critical temperature range (e.g. by melting) and which is converted back to a solid state when cooled 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 do not have thermoplastic properties or have thermoplastic properties comprising a melting temperature range significantly higher than that of the base polymer.

[0198] In the present context, a "non-liquefiable" material is generally understood to mean a material that will not liquefy at the temperatures reached during the process, in particular at the temperature at which the thermoplastic material of the first object is liquefied. It is not excluded that the non-liquefiable material will be able to liquefy at a temperature not reached during the process, which is generally much greater (e.g. greater than at least 80°C) than the liquefaction temperature of the thermoplastic material or the temperature at which the thermoplastic material is liquefied during the processing. The liquefaction temperature is the melting temperature of crystalline polymers. For amorphous thermoplastic materials, the liquefaction temperature (also referred to herein as the "melting temperature") is a temperature above the glass transition temperature at which the material becomes sufficiently flowable, sometimes referred to as the 'flow temperature' (sometimes defined as the lowest temperature at which extrusion is possible), e.g. the viscosity of the thermoplastic material drops below 10 4 The temperature of Pa*s (in embodiments, especially for polymers substantially without fiber reinforcement, is below 10 3 Pa*s).

[0199] For example, the non-liquefiable material may be a metal such as aluminum or steel, or a hard plastic such as a reinforced or unreinforced thermosetting polymer or a reinforced or unreinforced thermoplastic, the melting temperature (and / or glass transition temperature) of the thermoplastic being significantly higher than the melting temperature / glass transition temperature of the liquefiable part, for example, its melting temperature and / or glass transition temperature is at least 50°C or 80°C higher.

[0200] Specific examples of thermoplastic materials are: polyetheretherketone (PEEK), polyesters such as polybutylene terephthalate (PBT) or polyethylene terephthalate (PET), polyetherimides, polyamides, for example polyamide 12, polyamide 11, polyamide 6 or polyamide 66, polymethyl methacrylate (PMMA), polyoxymethylene or polycarbonate polyurethanes, polycarbonates or polyester carbonates, or also acrylonitrile butadiene styrene (ABS), acrylate-styrene-acrylonitrile (ASA), styrene-acrylonitrile, polyvinyl chloride (PVC), polyethylene, polypropylene and polystyrene, or copolymers or mixtures of these.

[0201] In embodiments where both the first and second bodies comprise thermoplastic materials and welding is not desired, the material pairing is selected such that the melting temperature of the second body material is significantly higher than the melting temperature of the first body material, for example at least 50° higher. A suitable material pairing is, for example, polycarbonate or polybutylene terephthalate (PBT) for the first body and polyetheretherketone (PEEK) for the second body.

[0202] In addition to thermoplastic polymers, the thermoplastic material may also include suitable fillers, such as reinforcing fibers, such as glass and / or carbon fibers. The fibers may be short fibers. Long fibers or continuous fibers may be particularly useful for parts of the first and / or second object that are not liquefied during processing.

[0203] The fiber material, if present, may be any known fiber reinforcement material, in particular carbon, glass, Kevlar aramid fibers, ceramics such as mullite, silicon carbide or silicon nitride, high strength polyethylene (Dyneema), and the like.

[0204] Other fillers which do not have a fibrous shape are also possible, such as powder particles.

[0205] Mechanical vibrations or oscillations suitable for embodiments of the method according to the invention preferably have a frequency between 2 and 200 kHz (more preferably a frequency between 10 and 100 kHz, or between 20 and 40 kHz for ultrasonic vibrations) and a vibration energy of 0.2 to 20 W per square millimeter of active surface. For example, the vibrating tool (ultrasonic welding electrode) is designed so that its contact surface oscillates mainly in the direction of the tool axis (longitudinal direction) and with an amplitude of between 1 and 100 micrometers, preferably about 30 to 60 micrometers. Such preferred vibrations are generated, for example, by ultrasonic devices known, for example, from ultrasonic welding.

[0206] In this document, the terms "proximal" and "distal" are used to indicate direction and position. That is, "proximal" refers to the side of the connection where the operator or machine applies mechanical vibration, while "distal" is the opposite side. In this document, the widening of the connection on the proximal side is called the "head", while the widening on the distal side is called the "foot". BRIEF DESCRIPTION OF THE DRAWINGS

[0207] In the following, embodiments of various aspects of the present invention are described with reference to the accompanying drawings. The accompanying drawings are schematic and not to scale. In the accompanying drawings, the same reference numerals represent the same or similar elements. The accompanying drawings are used to explain the present invention and the embodiments of the present invention, but are not intended to limit the scope of the present invention. Terms referring to directions such as "near", "far", etc. are used in the same way in all embodiments and drawings. The accompanying drawings show:

[0208] Figure 1 : A combining method, three initial configurations of a first object, a second object and a plurality of profile bodies, and the first and second objects combined by the combining method;

[0209] Figure 2 : A bonding method, wherein the second object comprises a profile body, and wherein the second object comprises a stress relief structure for reducing internal stress;

[0210] Figure 3 :according to Figure 2 Variations of the second object used in the method, including other mechanisms for stress relief;

[0211] Figure 4 : Possible arrangement of multiple profile bodies;

[0212] Figure 5 : Another possible arrangement of a plurality of profile bodies, which in combination with the shape of the object is correspondingly suitable for stress relief;

[0213] Figure 6 : Another possible arrangement of a plurality of profile bodies, which in combination with the shape of the object is correspondingly suitable for stress relief;

[0214] Figure 7-11 : A cross-sectional view of an exemplary profile body;

[0215] Fig.12 : An exemplary profile body including holes for anchoring;

[0216] Fig.13 : Another exemplary profile body including an undercut;

[0217] Fig.14 : Yet another exemplary profile body including an undercut;

[0218] Fig.15 : is a cross-sectional view of the profile body;

[0219] Fig.16 : Another bonding method, including twisting the profile body;

[0220] Fig.17 : A bonding method, wherein the second object comprises a reservoir for containing the thermoplastic material, which reservoir is displaced during embedding of the profile body;

[0221] Figure 18-19 : A method of combining, wherein the second object comprises a compensation area for deformation of the main body of the profile;

[0222] Fig. 20 : A bonding method, comprising a profile body having a proximal profile body head and a distal profile body head;

[0223] Fig.21 : an object joined by a method comprising a profile body having a proximal profile body head and a distal profile body head, and the second object comprises a reservoir and a compensation area;

[0224] Fig.22a - b: a profile body embedded in the first object and the second object, wherein the profile body comprises a support surface for limiting embedding in the first object and the second object;

[0225] Fig.23a - b: two embodiments of the profile body comprising a support surface;

[0226] Figure 24-27 : Various embodiments of a profile body including a support surface;

[0227] Fig.28 : A method of combining, wherein the profile body and the second object are integral;

[0228] Fig.29 : A method of combining, wherein the profile body is integral with the second object, and wherein the second object comprises a reservoir;

[0229] Fig.30 : An exemplary application of any embodiment of the bonding method using any embodiment of the profile body;

[0230] Figure 31-32 : The object shown is combined by a method comprising a profile body having a base element and an adhesive;

[0231] Figure 33-34 : Two embodiments of the profile body comprising a base element;

[0232] Figure 35-36 : After combining the first object and the second object, Fig.33 and 34 The main body of the profile;

[0233] Figure 37-39 : Other embodiments of the profile body including the base element;

[0234] Fig.40 :Provide a sealed bonding method;

[0235] Figure 41-42 : A bonding method comprising a profile body having a base element and an object having a reservoir for containing a thermoplastic material which is displaced during embedding of the profile body; and

[0236] Figure 43-45 : Other embodiments of the profile body comprising a base element. DETAILED DESCRIPTION

[0237] The method according to the invention comprises providing a first object 1, providing a second object 2 and providing a plurality of profile bodies 3. On the left, Figure 1 Three initial configurations of the provided first object 1 , second object 2 and a plurality of profile bodies 3 are shown.

[0238] In a first configuration, the first object 1 , the second object 2 and the profile body 3 are separate components.

[0239] In the second configuration, the second object 2 comprises a profile body 3, wherein as little stress as possible is to be introduced into the first object 1. In particular the first object 1 comprises a so-called A-surface 8 which is visible after joining of the first and second objects and which should not be deformed.

[0240] However, the second configuration may be constituted from the first configuration by a method comprising the step of embedding in the second object 2 the profile body 3 which is initially separated from the first object and the second object.

[0241] In a third configuration, the second object 2 comprises a profile body 3, wherein as little stress as possible is to be introduced into the second object 2. In particular, the second object 2 comprises an A-surface 8 which is visible after joining the first and second objects and which should not be deformed.

[0242] Likewise, the third configuration may be constructed from the first configuration by a method comprising the steps of embedding in the second object 2 a profile body 3 that is initially separated from the first object and the second object.

[0243] Apart from Figure 1 Embodiments of the method other than the embodiment of the method shown in can provide the first object 1, the second object 2 and the plurality of profile bodies 3 in one or more of the above configurations. Fig.19 and Fig. 20 The illustrated embodiment can provide the first object 1 , the second object 2 and the profile body 3 in a first configuration or in a second configuration.

[0244] exist Figure 1In the embodiment shown, both the first object and the second object comprise thermoplastic material. However, the second object 2 comprising thermoplastic material is an optional feature of the present invention. Fig.28 and Fig.29 An embodiment is shown in which the second object 2 does not comprise thermoplastic material.

[0245] Figure 1 The profile body 3 shown has the shape of a sleeve with a (longitudinal) axis 19 .

[0246] Independently of the initial configuration, the profile body 3 comprises a first profile body part 3.1 having a first undercut 4.1 and a first opening 16.1.

[0247] In order to combine the first object and the second object, the axis 19 is perpendicular to the surface portion of the first object 1 (hereinafter referred to as the first object surface portion 30) and the surface portion of the second object 2 (hereinafter referred to as the second object surface portion 31), wherein after the first object and the second object are combined, the first object surface portion 30 is attached to the second object surface portion 31.

[0248] The first profile body parts 3.1 with the first undercuts 4.1 and the first openings 16.1 are oriented towards the first object surface part 30 before the profile bodies 3, in particular their first profile body parts 3.1, are embedded in the first object 1 .

[0249] The profile body 3 may also comprise a second profile body part 3.2 having a second undercut 4.2 and a second opening 16.2. In particular, this is Figure 1 This is the case in the first construction shown, which means in an embodiment comprising a profile body 3 (which is separate from the first object and the second object) and comprising a second object 2 (which comprises a thermoplastic material), or more generally in a plurality of embodiments, wherein during bonding of the first object 1 to the second object 2, the profile bodies 3, in particular their second profile body parts 3.2, are embedded in the second object 2.

[0250] The profile body 3 may comprise a through opening from the first opening 16 . 1 to the second opening 16 . 2 .

[0251] The second profile body parts 3.2 with the second undercuts 4.2 and the second openings 16.2 are oriented towards the second object surface part 31 before the profile bodies 3, in particular their second profile body parts 3.2, are embedded in the second object 2.

[0252] exist Figure 1 The right side of shows the combined first and second objects, as they are constituted by any of the three configurations after the step of embedding the profile body 3 in the first object 1 and possibly in the second object 2 .

[0253] The profile body 3 is embedded by using a sonotrode 9 which is pressed against the coupling surface 32 of the first or second object.

[0254] In the embodiment shown, mechanical energy and pressure are applied using a sonotrode 9 for a sufficient time to embed the profile body 3 into the first object and possibly the second object, with the first object surface portion 30 resting against the second object surface portion 31 .

[0255] In an embodiment of the method in which the second object 2 also comprises a thermoplastic material, the method may comprise a step of interpenetrating the thermoplastic material of the first object 1 and the thermoplastic material of the second object 2 so that a weld is formed between the thermoplastic materials after resolidification of the thermoplastic materials. Said step may be performed after the step of embedding the profile body.

[0256] For example, a separate weld is formed beside each profile body 3. In particular, the weld can extend in a continuous, ie uninterrupted, manner around each profile body 3 so that it forms a seal.

[0257] Furthermore, due to the presence of the profile body 3, the weld does not need to be load-bearing or fixed. Thus, the weld can be a weld limited to a small volume, in particular a small volume extending around each profile body 3. Thus, the weld can be formed without or almost without additional energy input relative to the energy input generated by the mechanical energy and / or pressure applied during the step of embedding the profile body. Furthermore, such a weld and / or its contribution to the deformation of the first object and / or the second object and the generation of resistance to the movement of the first object 1 relative to the second object 2 can be substantially negligible.

[0258] Figure 2 An embodiment of the bonding method starting from the second configuration is shown. In this embodiment, the second object 2 comprises a stress relief structure which is a region 6.1 which is thinner than the region to which the profile body 3 is attached.

[0259] The thinned areas 6 . 1 are located between the areas to which the profile body 3 is attached.

[0260] The region in which the profile body 3 is attached has such a thickness that the profile body 3 does not penetrate the surface opposite to the second object surface portion 31. In the illustrated embodiment, the surface opposite to the second object surface portion 31 corresponds to the coupling surface 32.

[0261] The sonotrode 9 comprises a coupling surface 33 adapted to the shape of the second object 2. In particular, only the region to which the profile body 3 is attached is in contact with the sonotrode 9.

[0262] Figure 3The second object 2 shown comprises another stress relief structure, namely the corrugated portion 6.2. The corrugated portion 6.2 is equipped to deform in the presence of stress inside the second object 2. By doing so, the second object 2 can more easily compensate for deformations of the second object 2 relative to the first object 1 and vice versa. When not compensated, this relative deformation generates stresses in the first and second objects through the profile body 3. Thus, for example, the corrugated portion 6.2 is another mechanism to relieve stress and ensure that the A surface 8 is not deformed.

[0263] In the embodiment shown, the wave-shaped portion 6.2 is arranged in the thinned region 6.1.

[0264] Figure 4-6 An exemplary arrangement of the profile body 3 and an exemplary shape of the second object 2 are shown.

[0265] Figure 4 A second object 2 is shown having a circular cross-sectional shape in a plane parallel to the second object surface portion 31. The profile bodies 3 are equidistantly distributed, wherein the distance A between two adjacent profile bodies 3 is significantly greater than the diameter D of the profile bodies (or its corresponding extension perpendicular to the axis 19).

[0266] In many applications, the distance A is 2 to 10 times the diameter D (or its corresponding extension perpendicular to the axis 19 ), in particular 3 to 8 times or 4 to 6 times the diameter D. For example, the distance A may be 0.7 to 0.1 times the portion of the extension of the second object 2 in the direction of the two objects, which extension defines the distance A between two adjacent profile bodies 3 .

[0267] For example, the diameter D of the profile body 3 is between 1 and 10 mm, in particular between 2 and 8 mm, or between 3 and 6 mm.

[0268] The distance A between two adjacent profile bodies 3 is, for example, between 10 and 50 mm, in particular between 10 and 30 mm, or between 15 and 25 mm. The latter is particularly the case for second objects 2 which have a portion extending in the direction of the two objects, which defines a distance A between adjacent profile bodies 3 of about 40 to 50 mm.

[0269] The diameter D of the profile body 3 and the distance A between two adjacent profile bodies 3 depend on various parameters, such as the size of the objects to be bonded, the area in which bonding takes place and / or the required bonding strength.

[0270] Figure 4 The second object 2 includes a shell 7 which protrudes from a surface portion opposite to the second object surface portion 31 and is arranged so that it does not overlap with the profile body 3 at any position.

[0271] For example, the housing 7 may include wires or feedthroughs. Figure 4 The second object 2 shown can be used, for example, as a connection for supplying electricity, signals, liquids or gases.

[0272] Depending on the application and the space available nearby for installation, the cross-sectional shape of the second object 2 may have any other geometric shape, such as rectangular or elliptical.

[0273] exist Figure 5 In the embodiment of the invention, the cross-sectional shape of the second object 2 is adapted to the position of the profile body 3. The bonding takes place on a portion of the second object 2 protruding from a central portion of the second object 2. For example, the central portion comprises the housing 7.

[0274] In order to eliminate stresses caused by a movement of the second body 2 relative to the first body 2 and vice versa, the protrusion comprises a narrowing 6.3 between the position of the profile body 3 on the protrusion and the central area.

[0275] at last, Figure 6 Embodiments particularly suitable for large-scale binding and multi-point immobilization are shown.

[0276] exist Figure 6 In the embodiment shown, the second object 2 forms, for example, a two-dimensional regular grid around a central portion including the housing 7 .

[0277] The profile body 3 is positioned at the mesh intersections. The portion of the mesh located between the mesh intersections may also be a narrowing 6.3.

[0278] Figure 7-11 The profile body 3 is shown in a cross-sectional view perpendicular to the axis 19 of the profile body 3. The profile body 3 shown is equipped to deform elastically in response to a force applied from a direction perpendicular to its axis 19. Such a force is generated by the first object and the second object, which are deformed or moved relative to each other. Therefore, the use of a profile body 3 that can be deformed elastically in a direction perpendicular to its axis 19 helps to release the stress generated in the first object and the second object by said relative deformation or movement.

[0279] In particular in embodiments of the method in which the second object 2 comprises a thermoplastic material, Figure 7-11 The embodiment shown in may include a support surface 14 such as shown in Figures 22-27. The support portion 14 may be arranged on a mid-plane of the profile body 3, i.e., a plane perpendicular to the axis 19 and intersecting the axis 19 midway between the proximal and distal ends of the profile body 3.

[0280] exist Figure 7In the embodiment shown, the profile body 3 has a through opening from the first opening 16.1 to the second opening 16.2, and an open, ie discontinuous, for example spiral, cross section.

[0281] exist Figure 8 In the embodiment shown, the profile body 3 also has a through opening. However, the cross-sectional shape of the profile body 3 is that of an open ring.

[0282] Fig. 9 An embodiment of a profile body 3 is shown which is elastically deformable in response to a force applied from a direction perpendicular to the axis 19 but has a closed cross-sectional shape.

[0283] Fig. 9 An exemplary shape is shown of a trilobal profile body 3. However, other cross-sectional shapes are conceivable, including, for example, waves.

[0284] Fig.10 An embodiment of a profile body 3 is shown which has the shape of a curved line in a cross section perpendicular to the axis 19 .

[0285] Fig.11 An embodiment of a profile body 3 is shown which has the shape of a corrugation line in a cross section perpendicular to the axis 19 .

[0286] Figure 7 , Figure 8 , Fig.10 and Fig.11 An example of a cross-sectional shape corresponding to an open loop is shown, while Fig. 9 An example of a closed loop is shown.

[0287] according to Figure 7-11 An embodiment of the profile body 3 has a wall thickness which is configured not to prevent the profile body 3 from elastically deforming in response to a force applied from a direction perpendicular to the axis 19 .

[0288] In particular, the profile body is made of sheet metal.

[0289] A form-fit connection can be used in order to anchor the profile body 3 in the first object 1 and possibly in the second object 2 in a secure manner.

[0290] Figure 12-15 An embodiment of a profile body is shown which comprises means for facilitating a form-fitting connection when embedded in a thermoplastic material.

[0291] Fig.12 A profile body 3 is shown, which comprises a hole 15 in the wall of the profile body 3. In particular, the hole extends radially from the axis 19 of the profile body 3.

[0292] Fig.13A cross section through the profile body 3 is shown along the axis 19 of the profile body 19 .

[0293] The profile body 3 shown has a first undercut 4 . 1 in the region of the first opening 16 . 1 and a second optional undercut 4 . 2 in the region of the optional second opening 16 . 2 .

[0294] The undercut is arranged on the inner surface of the profile body 3 .

[0295] Fig.14 A profile body 3 is shown with an undercut 4 which is arranged on the outer surface of the profile body 3 .

[0296] Fig.15 A cross section of a profile body 3 is shown, wherein the undercut is arranged on the outer surface of the profile body 3, for example Fig.14 The profile body 3 shown in FIG. The cross section is a cross section along the axis 19 of the profile body 19 .

[0297] The profile body 3 shown comprises a first undercut 4.1 in the inner side of the profile body 3 in the region of the first opening 16.1 and a second undercut 4.2 at the outer surface of the profile body 3 in the region of the second opening 16.2.

[0298] Fig.16 An embodiment of a method is shown which comprises forming a profile body 3 with a twist 17. The twist 17 is a structure which, after embedding, can form a form-fitting connection with the first object 1. No undercut is therefore required.

[0299] In the embodiment shown, the profile body 3 is a twisted rod extending along the axis 19. Thus, if the second object 2 comprises a thermoplastic material, the second body portion 3.2 can also be embedded in the second object 2 by applying pressure and mechanical energy.

[0300] However, it is also possible to twist only the first profile body part.

[0301] exist Fig.16 In a variation of the embodiment shown, the first profile body portion 3.1 is at an angle to the second profile body portion 3.2, in particular at a right angle.

[0302] The second profile body part 3 . 2 can be twisted or attached to the second object 2 in different ways.

[0303] In particular, the first profile body part 3.1 comprises a twist 17, wherein the untwisted second profile body part 3.2 is attached in a recess of the second object surface part 31. In other words, the profile body does not penetrate the second object 2 deeply.

[0304] exist Fig.16In another variation of the illustrated embodiment, the first profile body portion and the second profile body portion are twisted and aligned along an axis 19. However, the axis 19 is oriented parallel to the first object surface portion and the second object surface portion.

[0305] Fig.17 The joining method is shown starting from the second configuration, i.e. the second object 2 comprises a profile body 3. However, attaching (eg embedding) the profile body 3 to the second object 2 before embedding the profile body 3 in the first object 1 may be a further step of the joining method.

[0306] The second object surface portion 31 comprises a recess protruding away from the second object surface portion 31 towards the portion of the second object 2 to which the profile body 3 is attached. The recess forms a reservoir 5 arranged to accommodate thermoplastic material of the first object 1 which is displaced during embedding of the profile body 3 in the first object 1, in particular in the first profile body portion 3.1.

[0307] The mechanical energy and pressure applied by the ultrasonic welding electrode 9 and coupled into the second object 2 and the profile body 3 cause a softening or liquefaction of the thermoplastic material of the first object 1, which is limited to a very local area around the area of ​​the first object 1, where the distal end of the profile body 3 is in contact with the first object 1.

[0308] Therefore, the reservoir 5 is arranged beside the profile body 3, and its shape can be adapted to the displacement of the thermoplastic material of the first object 1. In particular, the reservoir 5 can narrow from the second object surface portion 31 to the proximal direction, in particular to the location where the profile body is attached to the second object 2.

[0309] Fig.18 Another joining method starting from the second configuration is shown, i.e. the second object 2 comprises a profile body 3. However, attaching (e.g. embedding) the profile body 3 to the second object 2 before embedding the profile body 3 in the first object 1 may be a further step of the joining method.

[0310] Similar to Fig.17 In the embodiment shown in , the second object surface portion 31 comprises a recess protruding away from the second object surface portion 31 towards the portion of the second object 2 to which the profile body 3 is attached. However, the recess is dimensioned such that it forms a compensation area 10, which means an area in which a gap is created around a portion of the profile body 3 during the step of embedding the first profile body portion 3.1 into the first object 1, after joining the first and second objects and after a possible displacement of thermoplastic material to the compensation area 10.

[0311] The size of the compensation area 10 is such that the portion of the profile body 3 located in the gap after the first and second objects are combined includes a length so that the profile body 3 can follow the relative movement and deformation of the first and second objects by elastic deformation of the portion of the profile body 3 located in the gap after the combination.

[0312] In particular, the volume of the void is 0.5 times greater than the volume of thermoplastic material displaced during the step of embedding the first profile body 3.1 in the first object 1. For example, the volume of the void is the volume of thermoplastic material displaced or 1 to 3 times the volume of thermoplastic material displaced.

[0313] Thus, the volume of the compensation area 10 (ie before embedding the first profile body part 3.1 in the first object 1) is 1.5 times, for example 2 times or 2 to 4 times, greater than the volume of the displaced thermoplastic material.

[0314] Furthermore, the extension of the compensation area 10 parallel to the first body surface portion 30 is 1.2 times greater, in particular 2 times greater, than the corresponding maximum extension of the profile body 3. In particular, said extension is 1.2 times greater, in particular 2 times greater, than the maximum radial (relative to the axis 19 of the profile body 3) extension of the first profile body portion 3.1.

[0315] exist Fig.18 In a preferred embodiment of the method shown, the profile body 3 comprises a shape configured to elastically deform in response to a force applied in a direction perpendicular to its axis 19. For example, the profile body 3 comprises a Figure 7-11 Shape shown.

[0316] Fig.19 The functional principle of an embodiment including a compensation region 10 is shown, which uses the same Fig.18 The exemplary embodiment shown in FIG. 2 is compared to the example of a differently formed deformation region 10 .

[0317] The profile body 3 can be considered to include a portion embedded in the first object 1 (particularly the first profile body portion 3.1), a portion attached to the second object 2 (particularly the second profile body portion 3.2) and an unembedded portion between the two portions (which is located in the gap formed by the compensation area 10).

[0318] If the second object 2 moves relative to the first object 1 , the profile body 3 generates reduced resistance against the movement, thereby reducing stress around the parts of the first and second objects in which the profile body is embedded or attached, compared to embodiments without the compensation area 10 .

[0319] The stresses generated around said portions of the first and second bodies depend on the length of the non-embedded portion and on the elasticity of the non-embedded portion perpendicular to the axis 19 of the profile body 3 .

[0320] Fig. 20 An embodiment of the bonding method is shown, in which the profile body 3 comprises a proximal profile body head 13 and a profile body portion 12 located distally of the proximal profile body head 13 .

[0321] The profile body 3 has an overall height H from the proximal profile body head 13 to the distal end of the profile body portion 12, which is greater than the thickness T2 of the second object 2 (including possible reservoir 5 and / or compensation area 10) but less than the combined thickness of T2 and the thickness T1 of the first object.

[0322] The profile body 3 is configured to penetrate the second object 2 .

[0323] exist Fig. 20 In the illustrated embodiment, the profile body 3 is positioned relative to the proximal surface 11 of the second object 2 such that the profile body 3 is immediately adjacent to the connection location of the second object 2 .

[0324] The sonotrode 9 pushes the profile body 3 through the second object 2 and embeds the distal profile body head 12 by applying pressure and mechanical energy to the profile body head 13 .

[0325] Once the profile body head 13 is flush with the proximal surface of the connection location, the application of pressure and mechanical energy is stopped or reduced. Reducing the pressure and / or mechanical energy to a level insufficient for further embedding can improve the quality of the bond. In particular, it can prevent a gap from forming between the first object and the second object.

[0326] The difference between the height H of the profile body 3 and the thickness T2 of the second object 2 enables the distal profile body head 12 to penetrate deep enough into the first object to ensure a secure bond. In particular, the undercut 4.1 of the profile body 3 is completely embedded in the first object.

[0327] In the embodiment shown, the second body 2 comprises a thermoplastic material. However, this is an optional feature. Fig. 20 In the embodiment, it is required that the distal profile body head 12 can penetrate the second object 2. The second object 2 comprising or consisting of various materials can meet this need, possibly with the distal profile body head 12 adjusted accordingly, for example by being pointed.

[0328] Fig.21 Show according to Fig. 20 A variant of an embodiment in which the second object comprises a compensation region 10 and in which, due to the compensation region 10, the profile body has a height which takes into account the increased thickness T2 of the second object 2 at the connection location.

[0329] In the embodiment in which the first profile body part 3.1 is embedded in the first object 1 and the second profile body part 3.2 is embedded in the second object 2, i.e. in the embodiment according to the first configuration, the problem of insufficient embedding in the first object or the second object may occur. This is the result of softening or liquefaction of the thermoplastic material in contact with the first profile body part 3.1 relative to the softening or liquefaction of the thermoplastic material in contact with the second profile body part 3.2, for example, caused by unequal energy input.

[0330] This problem can be solved, for example, by using a support surface 14 as shown in FIGS. 22-27 . The support surface 14 is a surface of the profile body 3 which, during embedding, extends at least partially parallel to the first object surface portion 30 and at least partially parallel to the second object surface portion 31. Thus, the area of ​​the profile body 3 in contact with the first object surface portion 30 or the second object surface portion 31 increases as soon as the relevant surface portion comes into contact with the support surface 14. This prevents the profile body from being further embedded, because the amount of thermoplastic material that needs to be softened for further embedding increases, while the energy coupled into the thermoplastic material is constant.

[0331] The support surface 14 may form a closed volume which increases the resistance against further embedding once the volume is filled.

[0332] Fig.22a An embodiment of a profile body 3 is shown which comprises a support surface 14 after embedding the profile body 3 in the first object and the second object.

[0333] The profile body is sleeve-shaped, the support surface 14 being arranged inside the sleeve so that the sleeve comprises two compartments, wherein the first compartment is accessible through the first opening 16.1 and the second compartment is accessible only through the second opening 16.2.

[0334] Figure 22b Show Fig.22a A profile body 3, wherein the first profile body part 3.1 comprises a first axis 19.1, and the second profile body part 3.2 comprises a second axis 19.2 which is offset relative to the first axis 19.1.

[0335] 23 to 27 show further embodiments of a profile body 3 comprising a support surface 14 .

[0336] according to Figure 23a-23b and Fig.24 The embodiment includes an "X"-like cross-sectional shape parallel to the axis 19. Both embodiments do not include rotational symmetry about the axis 19, but include translational symmetry along an axis perpendicular to the illustrated plane.

[0337] Figure 23b Shown with offset axis Fig.23a Profile body.

[0338] It is conceivable to generally design the profile body with an offset axis. In particular, it is conceivable to Figure 24-27 Design profile body, but can also be based on Figure 7-19 Design the profile body with an offset axis.

[0339] according to Fig.25 The embodiment of is similar to the embodiment shown in Figure 22. However, the support surface 14 is displaced towards the first opening 16.1 in order to adjust the embedding depth in the first object and the second object.

[0340] In accordance with Fig.26 In the embodiment of the present invention, the support surface is realized by a diameter variation of the profile body 3. For example, the diameter of the sleeve-shaped profile body 3 increases stepwise from a first diameter of the first profile body part 3.1 to a second diameter of the second profile body part 3.2, or vice versa.

[0341] according to Fig.26 The profile body 3 comprises a support surface 14 located inside the profile body 3 for one of the objects to be bonded and located outside the profile body 3 for the other object to be bonded.

[0342] Fig. 27 An embodiment of a profile body 3 comprising a support surface 14 is shown, wherein the support surface 14 is a protrusion of the profile body 3 which is arranged on the outer surface of the profile body and extends radially from the axis 19 .

[0343] Likewise, the position of the support surface 14 may be adjusted to adjust the embedding depth in the first object and the second object.

[0344] Fig.28 An embodiment of the bonding method is disclosed, wherein the profile body 3 is an integral part of the second object 2 .

[0345] For example, the profile body 3 and the second object 2 are formed by and / or as a single element. However, the profile body 3 may be attached (eg glued or welded) to the second object 2.

[0346] The first profile body part 3.1 protrudes from the second object surface part 31. The first profile body part 3.1 comprises a first undercut 4.1 and a first opening 16.1.

[0347] The protruding first profile body part 3 . 1 forms a cavity through which the thermoplastic material of the first object 1 can penetrate during embedding of the profile body 3 in the first object 1 .

[0348] In the embodiment shown, the second object 2 comprises an A-surface 8. However, if the first object 1 also comprises an A-surface 8, the method will also work.

[0349] Fig.29 Show Fig.28 A variation of the embodiment shown, in which the second object 2 further comprises a reservoir 5 next to the protruding profile body 3. Thus, the thermoplastic material of the first object 1 can be contained in the cavity formed by the profile body 3 and the reservoir 5. This further reduces the pressure points and thus reduces the stress in the first and second objects.

[0350] Fig.30 Exemplary applications of any of the embodiments shown are shown including any of the profile bodies shown.

[0351] The present application relates to the fastening of a sensor 20 , for example a sensor 20 for a motor vehicle, for example a parking sensor.

[0352] The sensor 20 is a part of the second object 2 which forms a connection piece including an opening for the electrical wire 21 .

[0353] The first object 1 to which the connector is connected is, for example, an automobile component, which comprises a surface that is part of the visible outer surface of the automobile. In other words, the automobile component comprises an A-surface 8 .

[0354] Fig.31 An embodiment of a second object 2 bonded to a first object 1 by means of a profile body 3 comprising a base element 34 and an adhesive 40 is shown. The second object 2 is drawn in a transparent manner to show in more detail the profile body 3 and the adhesive 40 arranged between the first and second objects.

[0355] Fig.32 express Fig.31 Cross-sectional view of .

[0356] The profile body 3 comprises a first profile body portion 3.1 and a second profile body portion 3.2. The first profile body portion and the second profile body portion are arranged on opposite sides of the base element 34, namely on the first surface 35 and the second surface 36.

[0357] The first profile body part 3.1 protrudes from the base element 34 along a first axis 19.1 and the second profile body part 3.2 protrudes from the base element 34 along a second axis 19.2.

[0358] according to Fig.31The embodiment shows a set of optional features of the first axis 19.1, which are offset from a set of second axes 19.2 along the plane defined by the base element 34, the optional features of the first axis and the second axis extend perpendicular to the plane defined by the base element 34, the optional features of the first axis 19.1 are parallel to each other and the optional features of the second axis 19.2 are parallel to each other.

[0359] Fig.31 and 32 (as well as Fig.35 and 36 ) The second object 2 of the embodiment shown in ) comprises a thermoplastic material. Therefore, the second profile body part 3.2 is embedded in the second object 2.

[0360] Fig.31 The embodiment shown comprises the optional feature of the first profile body part 3.1 forming a first undercut 4.1, the first undercut 4.1 forming by its shape a first cavity 37, the first cavity 37 having a diameter that decreases along the first axis 19.1 when starting from the base element 34 (from the first surface 35). It also comprises the optional feature of the second profile body part 3.2 forming a second undercut 4.2, the second undercut 4.2 forming by its shape a second cavity 38, the second cavity 38 having a diameter that decreases along the second axis 19.2 when starting from the base element 34 (from the second surface 36).

[0361] according to Fig.31 and 32 The first and second objects are shaped such that an adhesive gap 41 is formed during bonding of the first object 1 to the second object 2. For this purpose, the first object 1 comprises a recess in a first object surface portion 30 (i.e. a surface portion arranged towards the second object 2 during / after bonding) and / or the second object 2 comprises a recess in a second object surface portion 31 (i.e. a surface portion arranged towards the first object 1 during / after bonding).

[0362] The size of the adhesive gap 41 , that means the distance between the first and second object in the region of the adhesive 40 after bonding is given by the depth(s) of the recess(es) and the thickness of the base element.

[0363] The profile body 3 is arranged in such a way that it does not extend into the recess(es) before the step of inserting the profile body 3 .

[0364] In the step of arranging the first object 1, the second object 2, the profile body 3 and the adhesive 40, which step is before the step of embedding the profile body 3, the adhesive 40 is arranged in a recess or on a surface portion of the first object or the second object, which recess or surface portion forms a part of the adhesive gap 41 during / after bonding the first object 1 to the second object 2.

[0365] However, it is also conceivable to arrange and / or preassemble the adhesive 40 together with the profile body 3, and optionally together with an object. In particular, the adhesive 40 can be arranged in contact with the first profile body part or the second profile body part. In this embodiment, the profile body part in contact with the adhesive 40 penetrates the adhesive 40 at least during the step of embedding the profile body 3.

[0366] Fig.33 and Fig.34 Two further embodiments are shown which comprise a base element 34 and which bring about the creation of an adhesive gap 41 during the bonding of a first object 1 to a second object 2 .

[0367] In accordance with Fig.33 The shapes of the first profile body part and the second profile body part are shown in the embodiment, optionally combined with the mechanical properties of the adhesive 40 determining the size of the adhesive gap 41, which means the distance between the first object and the second object in the area of ​​the adhesive 40 after bonding.

[0368] In particular, when starting from the first opening 16.1, the outer diameter of the first profile body part 3.1 increases along the first axis 19.1, and when starting from the second opening 16.2, the outer diameter of the second profile body part 3.2 increases along the second axis 19.2. However, it is also conceivable that the first profile body part 3.1 or the second profile body part 3.2 is shaped in this way and the base element 34 forms the support surface 14.

[0369] Fig.35 It is shown that after combining the first object and the second object, according to Fig.33 A cross-sectional view of the profile body 3.

[0370] In accordance with Fig.34 In the embodiment of the present invention, the base element 34 forms a spacer. For this purpose, the base element comprises a thickness corresponding to the desired adhesive gap size, which means the desired distance between the first object and the second object after bonding.

[0371] Fig.36 It is shown that after combining the first object and the second object, according to Fig.34 A cross-sectional view of the profile body 3.

[0372] The dimensions of the profile body 3, in particular the dimensions of the profile body including the base element 34, can be adapted to at least one of the shapes of the first object and / or the second object and other elements present on or mounted to the first object and / or the second object. Feedthroughs, cables, mountings, sensors, etc. are examples of such other elements. In particular, the dimensions can be adapted to the available space for fixing.

[0373] Alternatively or additionally, the arrangement of the first profile body portion and the second profile body portion may be adapted to at least one of the shape of the first object and / or the second object and other elements present in or mounted to the first object and / or the second object.

[0374] Figure 37-39 A further embodiment of a profile body is shown which comprises a base element 34 which is similar in design to the Figure 31-36 The embodiments shown in differ in particular in their dimensions and the arrangement of the first profile body part and the second profile body part.

[0375] like Figure 31-37 and Fig.39 As shown, the first profile body part 3.1 offset from the second profile body part 3.2 is advantageous for the manufacture of the profile body 3. When the first profile body part and the second profile body part are arranged in this way, the profile body parts can be punched (stamped) from the base element 34.

[0376] However, production methods such as 3D printing, injection molding, folding a semi-finished profile body (including a profile body portion only on one outer surface) or joining two such semi-finished profile bodies along a surface that does not include a profile body portion, allow for a first profile body portion 3.1 protruding from an area on the first surface 35 and a second profile body portion 3.2 protruding from an area on the second surface 36, wherein the projection of the area on the first surface 35 overlaps with the area on the second surface 36, and vice versa. Fig.38 An embodiment of such an arrangement of a first profile body part and a second profile body part is shown.

[0377] For example, such an arrangement of the first profile body part and the second profile body part is advantageous with regard to the mechanical stability of the combined first and second object.

[0378] exist Fig.38 In the embodiment of FIG. 5 , such an arrangement of the first profile body portion and the second profile body portion is realized by the profile body 3 , which includes a first profile body component 61 and a second profile body component 62 .

[0379] The first profile body part 61 comprises a profile body portion only on one side, and the second profile body part 62 comprises a profile body portion only on one side.

[0380] The side opposite to the side including the profile body portion does not include any profile body portion on the two profile body parts. However, the sides not including the profile body portion are adapted to each other so that the first component and the second component can be abutted along the sides and fixed in an abutted relative position.

[0381] In the embodiment shown, the first and second components are fixed together by welding (weld points 63 ).

[0382] exist Fig.38 In an embodiment, the first profile body component and the second profile body component are metal plates, wherein the profile body portion is punched out of the metal plates.

[0383] also, Figure 37-39 The embodiment shown is Figure 31-36 The embodiment shown differs in the thickness of the base element 34. By doing so, the size of the adhesive gap 41 and / or the mechanical stability of the profile body 3, in particular the rigidity or the bending properties, can be determined.

[0384] The embodiment shown is planar and non-curved. However, it is also conceivable to design the profile body 3, in particular the base element 34, to be non-planar and / or curved.

[0385] Fig.40 The main elements of the bonding method are shown, which seals the area between the bonded first and second objects. The elements are shown in cross-sectional views before (left side of the figure) and after (right side of the figure) bonding.

[0386] For this purpose, one of the objects, for example the second object 2, comprises an elastomeric portion 50 which is arranged in a compressed manner between the first object and the second object during and after the bonding. The compressed elastomeric portion 50 seals an area on one side of the elastomeric portion 50 with an area on the other side of the elastomeric portion 50.

[0387] The elastomeric portion 50 may have a closed form so that the area enclosed by the elastomeric portion 50 is sealed from the outside. This allows, for example, for components that are adversely affected by moisture and / or humidity to be installed in the area enclosed by the elastomeric portion 50 or to be accessible in or through this area.

[0388] The profile body 3 can be arranged in the surrounding area or in the outer area.

[0389] A separate sealing element instead of the elastomeric portion 50 is also conceivable.

[0390] Fig.41 An embodiment of the method is shown, in which a profile body 3 having a base element 34 and a plurality of profile body parts (3.1 and 3.2) is combined with a reservoir 5, which is arranged such that the thermoplastic material is displaced during a step of embedding the profile body 3 in a first object 1 and / or is accommodated in the reservoir 5 during a step of embedding the profile body 3 in the first object 1 and a second object 2.

[0391] For this purpose, the reservoir 5 is arranged on the first body 1 and, as the case may be, on the second body 2 in a manner adapted to the arrangement of the profile body portion.

[0392] The profile body part shown comprises openings (16.1 and 16.2) so that the thermoplastic material can penetrate into the cavity formed by the profile body part.

[0393] In the embodiment shown, the undercuts (4.1 and 4.2) are formed by the shape of the cavity.

[0394] Fig.42 The embodiment of FIG. 3 illustrates an optional feature of a surface opening for accommodating the base member 34 .

[0395] In the embodiment shown, the first object 1 comprises a first surface opening 45 forming a recess, the depth of which corresponds to at least half the thickness of the base element 34, and the second object 2 comprises a second surface opening 46 forming a recess, the depth of which corresponds to at least half the thickness of the base element 34.

[0396] Other depths of the first surface opening and the second surface opening can also be envisioned to accommodate the base element 34. For example, the base element 34 can be mainly accommodated in one of the two surface openings. Alternatively, there can be a first surface opening 45 or a second surface opening 46, wherein the surface opening has a depth that corresponds at least to the thickness of the base element 34.

[0397] according to Fig.42 The embodiment results in a gap-free joining of the first object 1 and the second object 2, wherein according to Fig.41 Embodiments of the invention create a gap, such as an adhesive gap 41 between the first object and the second object.

[0398] Fig.43 The basic structure of the profile body 3 is shown. The profile body 3 includes a first profile body part 3.1 ( Fig.43 1 ) and a second profile body portion 3.2 on the second surface 36, the second profile body portion 3.2 being offset from the first profile body portion 3.1.

[0399] This basic configuration is sufficient for a wide variety of applications. However, the stability of the bond between the first object 1 and the second object 2 created by the profile body 3 in the basic configuration may be insufficient if the objects are pulled apart during use, for example if a force is applied to one object which creates a significant force component perpendicular to the surface portion of the first object and the surface portion of the second object (35 and 36), while the other object is mounted so that it cannot move in a direction perpendicular to the surface portion of the first object and the surface portion of the second object. This insufficient stability is a result of a (rotational) moment created on the profile body 3. This moment can cause deformation of the base element 34, in particular of the area between the two profile body parts.

[0400] Particularly if the profile body is made of sheet metal, there may be a lack of mechanical stability.

[0401] A first way to overcome the problem of insufficient mechanical stability of the profile body 3 in the basic configuration is to choose a material that makes the profile body more stable and / or makes the base element 34 thicker. However, this approach may not be suitable in terms of manufacturing costs.

[0402] A second way to overcome the problem of insufficient mechanical stability of the profile body 3 in the basic configuration is to reduce the distance between the profile body parts and / or to reinforce the area between two profile body parts, for example by ridges and / or struts.

[0403] A third way to overcome the problem of insufficient mechanical stability of the profile body 3 in the basic configuration is to arrange at least one further profile body part in such a way that the moments on the base element are reduced. An example of the resulting configuration is shown in Fig.44 and 45 Shown in.

[0404] exist Fig.44 In the embodiment shown, the additional profile body parts are added in alignment with the first and second profile body parts of the basic configuration. The additional profile body parts are oriented so that the moment on the area between the profile body parts is reduced. In the embodiment shown, this means that the first and second profile body parts are arranged in an alternating manner along the line.

[0405] exist Fig.45 In the embodiment, a plurality of second profile body parts 3.2 (for example, three) are arranged around the position of the first profile body part 3.1.

[0406] Features of at least two of the first, second and third methods may be combined in order to produce an even more stable profile body.

[0407] All profile bodies 3 shown in the figures may be used in combination with at least one of an adhesive 40, an elastomeric portion 50 (or another sealing element), a reservoir 5, a surface opening (45, 46), or without any of these features.

Claims

1. A profile body (3) for joining a first object (1) to a second object (2), wherein the first object (1) and the second object (2) both comprise thermoplastic material, wherein the profile body (3) comprises a vertical axis (19) and a first profile body part (3.1) and a second profile body part (3.2), the first profile body part (3.1) having a structure suitable for forming a form-fitting connection and a first opening (16.1), and the second profile body part (3.2) having a structure suitable for forming a form-fitting connection and a second opening (16.2), wherein the profile body (3) forms an open ring in a cross section perpendicular to the axis (19), the open ring comprising at least two ends bent towards each other, wherein the height of the first profile body part (3.1) and the second profile body part (3.2) is between 0.3 mm and 2 mm, and wherein the profile body (3) comprises a metal or polymer The invention relates to a material comprising a first object and a second object, wherein the metal or polymer is liquefiable only at a temperature much higher than the thermoplastic material of both the first object and the second object, wherein the structure of the first profile body part (3.1) and / or the second profile body part (3.2) suitable for forming a positive connection is at least one of an undercut, a hole and a distortion, wherein the first profile body part (3.1) and the second profile body part (3.2) are oriented in opposite directions, wherein the profile body (3) further comprises a base element (34) having a first surface (35) and a second surface (36), wherein the first profile body part (3.1) protrudes from the first surface (35) and the second profile body part (3.2) protrudes from the second surface (36), wherein the base element (34) is formed with a support surface (14), which is arranged to determine the maximum penetration depth of the profile body (3) in at least one of the first object (1) and the second object (2).

2. The profile body according to claim 1, wherein the profile body (3) is designed to generate a resistance against embedding the profile body (3) into at least one of the first object (1) and the second object (2), the resistance increasing according to the embedding depth.

3. The profile body according to claim 1 or 2, wherein the base element is designed to create an adhesive gap when the profile body (3) bonds the first object (1) to the second object (2).

4. The profile body according to claim 1 or 2, wherein the first profile body part (3.1) and the second profile body part (3.2) are offset from each other.

5. The profile body according to claim 1 or 2, wherein the diameter (D) of the first profile body part (3.1) and / or the second profile body part (3.2) is between 1 mm and 10 mm.

6. The profile body according to claim 1 or 2, wherein the distance (A) between a first profile body portion (3.1) and an adjacent second profile body portion (3.2) is 2 to 10 times the diameter (D) of the first profile body portion (3.1) and / or the second profile body portion (3.2).

7. Profile body according to claim 1 or 2, wherein the distance (A) between a first profile body part (3.1) and an adjacent second profile body part (3.2) is reduced to provide sufficient mechanical stability.

8. Profile body according to claim 1 or 2, wherein the area between a first profile body part (3.1) and an adjacent second profile body part (3.2) is reinforced by ridges and / or struts.

9. The profile body according to claim 1 or 2, wherein the thickness of the base element is less than 1 mm.

10. The profile body according to claim 1 or 2, wherein the profile body (3) can have a substantially cylindrical shape.

11. The profile body according to claim 1 or 2, wherein the profile body (3) can form a cavity that can be accessed from the first opening (16.1) or the second opening (16.2).

12. The profile body according to claim 1 or 2, wherein the aspect ratio of the profile body (3) is less than 2.

13. The profile body according to claim 1 or 2, wherein the profile body (3) has an open ring, a spiral or a corrugated shape in a cross section perpendicular to its axis (19).

14. The profile body according to claim 1 or 2, wherein the profile body (3) is symmetrical under a rotation of 120 degrees or 90 degrees.

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