Combine objects together

Abstract

The present invention relates to the fields of mechanical engineering and manufacturing, in particular to the fields of mechanical manufacturing, such as the field of automotive engineering. The present invention relates to a method for joining a first object (1) to a second object (2). The method comprises the following steps: providing the first object (1) comprising a thermoplastic material (3) in a solid state, providing the second object (2) comprising a proximal side (4), applying a mechanical pressing force capable of liquefying the thermoplastic material (3) and a mechanical stimulation until a flowing portion of the thermoplastic material is able to flow and penetrate into a structure (10) of the second object (2), and stopping the mechanical stimulation and resolidifying the thermoplastic material to form a form-fitting connection between the first object and the second object. In the method according to the invention, the provided second object (2) comprises a low-density area (22), wherein the protrusion (9) at least partially penetrates into the low-density area (22) before the thermoplastic material becomes flowable, and wherein the first object (1) comprises a protruding portion (91) after the step of resolidifying the thermoplastic material, wherein the protruding portion (91) at least partially penetrates into the low-density area (22). The invention also relates to a device, in particular a connector, which is designed to be coupled to an object using the method according to the invention.

Description

[0001] This application is a divisional application of Chinese invention patent application No. 201880032882.6, entitled “Combining Objects Together”, with a filing date of March 20, 2018. Technical Field

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

[0003] Devices used or manufactured in the automotive, aerospace, and other industries include surfaces that must meet physical requirements imposed by users or authorities. These requirements relate, in particular, to optical, acoustic, thermodynamic, and mechanical properties. For example, the quality and value of the device are closely linked to the visual impression given by the exterior surface, noise due to vibrations or internal components of the device must be limited and / or controlled, and the surface must provide a specific feel and / or resistance to degradation due to use.

[0004] A cover attached to a surface is one way to meet the requirements. Thus, there are currently two methods, either attaching the cover directly to the surface or attaching a connector to the cover by which the cover can be attached to the surface.

[0005] The first method involves the use of adhesives. However, adhesives are disadvantageous in terms of long-term stability. Specifically, if adhesives are used to attach the cover to, for example, a porous and / or fibrous surface or to, for example, a porous and / or fibrous surface, stability is poor because the adhesive is embedded only in the outermost portions of the fibrous and / or porous material and contributes to the bonding.

[0006] Furthermore, the use of adhesives is time-consuming (eg due to the hardening process), typically requires large areas to be processed and may be limited to certain body sizes, eg as is the case with friction welding.

[0007] The second method typically uses fasteners that can penetrate the cover. Examples of such fasteners are rivets, nails, and screws. The use of fasteners and related methods based on penetration through holes prepared during the attachment or pre-drilling process are disadvantageous, at least in terms of optical and acoustic performance.

[0008] Thus, there is a need for alternative methods of bonding objects together, particularly bonding coverings having specific physical properties to surfaces of devices such as motor vehicles and machines. Summary of the Invention

[0009] It is an object of the present invention to provide a method for joining objects together which overcomes the disadvantages of prior art methods.

[0010] Specifically, an object of the present invention is to provide a method for bonding a first object to a second object, wherein one of the first object and the second object has a specific density distribution, which is determined by requirements related to at least one of acoustic (e.g., damping) properties, thermodynamic (e.g., insulation) properties, mechanical properties, and optical properties.

[0011] The mechanical properties may include the generation of a specific (eg soft) feel and / or a high resistance to degradation due to frequent use.The optical properties may rely on the requirement for a surface that is not affected by bonding the first object to the second object.

[0012] The method according to the present invention is suitable for bonding a first object to a second object. In its basic embodiment, the method comprises the following steps:

[0013] • Providing a first body, wherein the first body extends between a proximal end and a distal end, wherein the first body comprises a thermoplastic material in a solid state.

[0014] • Providing a second object comprising a proximal side.

[0015] Applying a mechanical compressive force and a mechanical stimulus capable of liquefying the thermoplastic material to at least one of the first object and the second object until the flow portion of the thermoplastic material is able to flow and penetrate the structure of the second object.

[0016] • Ceasing the mechanical actuation and allowing the thermoplastic material to resolidify to form a form-fitting connection between the first object and the second object.

[0017] A basic embodiment of the method is characterized in that the provided second body comprises a low-density region and in that the distal end at least partially penetrates the low-density region before the thermoplastic material becomes flowable.

[0018] The low-density region that is at least partially penetrated by the distal end before the thermoplastic material becomes flowable is not necessarily the region of lowest density of the second object. This also means that the first object is not necessarily anchored in the region of lowest density of the second object.

[0019] For example, the at least partially distally penetrated low-density region may form a substrate for an even lower-density region, which forms an exposed surface of a first object. This embodiment may exist, for example, in a case where the body part forms part of the first object and the cover part forms the second object.

[0020] Preferred embodiments may include at least one of the following features:

[0021] The step of applying a mechanical excitation comprises applying a mechanical oscillation along an axis extending at an angle with respect to the proximal side, the proximal side of the second object being provided to have a low density.

[0022] At least in this embodiment, the low-density region extends in the normal direction of the proximal side (that is, on its distal side). The low-density region may be a low-density region on the proximal side. The low-density region on the proximal side may include the proximal side.

[0023] A first object is provided comprising a first object body and at least one protrusion located distally of the first object body, wherein the protrusion forms a distal end and comprises a thermoplastic material in a solid state.

[0024] In this embodiment, the protrusion (or protrusions) at least partially penetrate the low density region before the thermoplastic material becomes flowable. Additionally, the first object comprises a protruding portion after the step of resolidifying the thermoplastic material, wherein the protruding portion at least partially penetrates the low density region.

[0025] • The step of at least partially varying the compressive strength of the low density region.

[0026] In this context, the term "compressive strength" refers to the maximum force per square millimeter that a region generates before it is displaced, meaning that the region is further compressed before the material is restrained. Thus, compressive strength can also be viewed as resistance to further compression or as stiffness.

[0027] The compressive strength corresponds, for example, to the stress as measured in a stress-strain experiment.

[0028] The change in compressive strength (stress) can cause the applied mechanical compressive force and mechanical stimulation to cause the thermoplastic to liquefy. In other words, the low-density region cannot provide the compressive strength required to liquefy the thermoplastic material during the step of applying the mechanical compressive force and mechanical stimulation without changing the compressive strength.

[0029] The step of at least locally varying the compressive strength of the low-density region may be performed until a critical compressive strength is formed, that is to say until the compressive strength required for liquefaction of the thermoplastic material by the applied mechanical pressing force and mechanical stimulation is reached.

[0030] The compressive strength required to liquefy the thermoplastic material during the step of applying the mechanical pressing force and the mechanical stimulation may vary depending on the mechanical pressing force and the mechanical stimulation applied.

[0031] Specifically, the change in compressive strength refers to an increase in compressive strength.

[0032] In many embodiments, the increase in compressive strength is caused by at least partial compression of the low-density region. In other words, the method may include the step of at least partial compression of the low-density region.

[0033] In particular, the compressive strength may depend on the densification of low-density regions, wherein said densification is caused by compression.

[0034] The low density regions may be compressed by mechanical compressive forces applied to liquefy the thermoplastic material.

[0035] In the step of applying mechanical pressing force and mechanical stimulation for liquefying the thermoplastic material, mechanical stimulation may be applied after compression of the low-density region has caused an increase in compressive strength sufficient for liquefying the thermoplastic material by the applied mechanical pressing force and mechanical stimulation.

[0036] The step of at least locally changing the compression strength of the low-density area or the step of at least locally compressing the low-density area can make the method suitable for joining a first object to a second object by means of a form-fitting connection between the first object and the second object, wherein the form-fitting connection is established in an area of ​​the second object corresponding to the low-density area before joining the first object to the second object.

[0037] In an embodiment, the low density region is formed substantially of a non-viscous material, which means a material comprising components that only weakly interact with each other, for example when subjected to an external force, such as a compressive force.

[0038] An example of a non-adhesive material is a material comprising or consisting of fibers that are able to move relative to each other to a certain extent under the influence of an applied force.

[0039] The provided second object need not contain weak interactions between the components. Rather, the weak interactions may be the result of forces acting on the second object during the method. Such forces may cause the destruction of connections between the components. For example, the material may include fibers partially connected by a bonding material, such as a resin powder or melted fibers combined with a heat treatment, to define a specific density of the material.

[0040] In many embodiments, the protrusion or protrusions are distal ends that penetrate or pass through the second object.

[0041] In this article, any relative arrangement in an object, article, device etc. and any relative arrangement between an object, article, device etc. are all given relative to the origin being positioned at the middle position of the first object. When no other statements are given, the surface of the object arranged closest to the origin is referred to as the near side of the object, and the relative surface of the object (for example, the corresponding surface being arranged on the opposite side of the object) is referred to as the far side. In the example of the first object, the surface pointing to the near side of another object to which the first object will be set to contact and / or (depending on the situation) be coupled is referred to as the far side of the first object. In other words, the near side is always in contact and / or (depending on the situation) coupled with the far side in this method. Thus, (multiple) protrusions are arranged on the far side of the first object.

[0042] In many embodiments, the protruding portion refers to a portion of the protrusion remaining after the step of allowing the thermoplastic material to resolidify, wherein the portion (here, the protruding portion) is not limited to the outermost area of ​​the second object, but extends into the volume of the second object. Remaining means that the material defining the protruding portion does not penetrate into the structure of the second object.

[0043] The distance that the projection penetrates the second object depends on the application. However, the penetration depth of the projection in the normal direction of the near side surface of the second object is usually greater than the elongation of the projection in a direction parallel to the near side surface of the second object. This means that the ratio of the elongation in the normal direction of the near side surface to the elongation parallel to the near side surface is at least 1, in particular between 1 and 5, for example between 1.5 and 4 or between 2 and 3.

[0044] Slightly different definitions of protrusions and / or other features characterizing protrusions are given below.

[0045] In this context, a low-density surface or area means that it is at least one of porous, fibrous and soft and / or includes a variety of structures, holes, openings, etc. The structures, holes and / or openings can be used for damping, such as sound damping and / or vibration damping.

[0046] In embodiments, particularly those including a method step of compressing the low-density region as described in detail below, the low-density region can be compressed along the axis along which the mechanical compressive force is applied during the steps of applying the mechanical compressive force and mechanically stimulating. The compression can result in a thickness reduction of the low-density region of, for example, 10-90%, where the thickness is measured along the axis along which the mechanical compressive force is applied. Specifically, the thickness can be reduced by 30-90%, such as 60-80%, or by 20-80%, such as 30-70%.

[0047] The compression ratio is another measure of the compression of the low-density area. In particular, the compression ratio is a suitable measure when considering compression. The compression ratio in the protruding area can be between 1.1 and 10, in particular between 1.25 and 5, for example between 1.4 and 3.3.

[0048] The material or material composition forming the low-density area may be locally compressed. For example, a local mechanical load such as formed by a protrusion of the first object or a protruding area of ​​an article attached to the second object may cause local compression of the low-density area.

[0049] The local and / or "global" compression of the low-density region can be elastic or predominantly elastic. This means that the compression relaxes (disappears) or largely relaxes after the mechanical load causing the compression is removed. In other words, the provided second object is elastically deformable. The applicability of the bonding method to elastically compressible second objects also offers significant advantages over known bonding methods based on rigid (here, incompressible) objects or objects comprising only plastically deformable (here, irreversibly deformable) parts, such as hollow core boards (HCBs).

[0050] Thus, in many embodiments, a low-density surface or region not only refers to a surface or region having at least one of the properties of being porous, fibrous, and soft and / or comprising a variety of structures, holes, openings, etc., but also refers to a compressible, in particular elastically compressible, surface or region. In addition, the surface or region is locally compressible, meaning that it can be compressed in such a way that it can include differentiated compressed areas.

[0051] This compression may result in an increase in compressive strength.

[0052] In an embodiment, the second object may be composed of a second object component, and the structure of the second object may be inherently formed by the component. For example, the structure may be a pore, a hole, a channel, etc.

[0053] For example, the second object may include or be composed of fibers, textile materials, foam, porous materials, cardboard, etc. It may be formed from a series of layers, some of which may have at least one of the following properties: rigidity, incompressibility, density (herein meaning a low concentration of pores, holes, channels, etc.), and load-bearing properties. The second object and / or the layers forming the second object may have positionally related components. Additionally or alternatively, the order of the layers may be positionally related.

[0054] In particular, in embodiments of the method in which the protrusion is formed after the step of resolidifying the thermoplastic material, the structure achieves depth-dependent anchoring, meaning anchoring not only on the surface of the second object but also within the volume of the second object. However, embodiments are conceivable in which a specific structure for depth-dependent anchoring is not required. Examples of such embodiments are embodiments comprising a proximal top layer as described below, or embodiments intended to attach a third object as described below, wherein the third object ensures at least partial penetration of the protrusion into the low-density area.

[0055] Additionally or alternatively, one could also envisage forming the structure of the second object, for example by a roughened surface of the second object and / or by using a production process of the second object for forming such a structure.

[0056] Mechanical excitation can be initiated after, before, or simultaneously with the application of mechanical compressive force. Initiating mechanical compressive force before mechanical excitation is advantageous in terms of bond quality, particularly bond depth and the resulting bond strength. However, one can envision configurations in which mechanical excitation can help optimize the penetration performance of the protrusion(s). Some of these configurations are discussed below.

[0057] The mechanical compressive force may continue for a time sufficient to allow the thermoplastic material to resolidify after the mechanical stimulus ceases.

[0058] The mechanical pressing force may be varied during the steps of applying the mechanical pressing force and the mechanical actuation and, as appropriate, during the resolidification of the thermoplastic material.

[0059] The thermoplastic material of the first object can become flowable by absorbing mechanical energy generated by mechanical excitation (particularly mechanical oscillation / vibration) when the objects are pressed against each other. For example, mechanical vibration energy can be coupled through the first object and / or the second object to the interface formed by the thermoplastic material of the first object and the material of the second object. At this interface, external and possibly internal friction will cause the thermoplastic material to heat up and become flowable. The flowable thermoplastic material will then be pressed into the structure of the second object due to the applied pressure.

[0060] The portions of the first and / or second object forming the interface may comprise contours that act as energy directors, ie energy absorption and energy generation will automatically be focused on or around the respective interface.

[0061] In an embodiment, the second object is provided to include a density distribution that increases in relation to the distance from the proximal side, in particular, the density increases in a distal direction orthogonal to the proximal side.

[0062] The increase in density may be continuous or stepwise.

[0063] If the second object extends between the proximal side and the distal side, the density can only be increased within a limited extent of the second object.

[0064] The low-density region may be located on the proximal side, the low-density region may be located on the distal side, or the low-density region may be located somewhere between the proximal and distal sides.

[0065] One can also envision a second low-density region, for example one low-density region at the proximal side and another low-density region at the distal side.

[0066] In an embodiment, the second object includes a low-density region located at the proximal side (ie, the low-density region is the proximal region) and another high-density region located distal to the low-density region.

[0067] The low density region is followed by a region that is less dense than (ie, denser than) the high density region.

[0068] The term "high density" in the high-density region or high-density region is used to express the density of the region relative to the density of another region (especially the low-density region). However, this term does not necessarily mean that the "high-density" region does not include a variety of structures, holes, openings, etc. The term also does not mean that the region is incompressible or that there is no need to compress the region to form a critical density and / or compression strength (details are described below). More precisely, the region may also have all the physical properties attributed to the low-density region. However, the second object includes at least one region having a lower density than the "high-density" region.

[0069] In another embodiment, the further region is arranged distal to the low-density region, wherein the low-density region is not located at the proximal side.

[0070] Alternatively or in addition to the further region, the low-density region can have a density that increases as a function of the distance from the proximal side.

[0071] In an embodiment, a second object is provided comprising a proximal top layer, wherein the low-density region is arranged distally of the proximal top layer, and wherein the method comprises the step of forcing the protrusions to penetrate the proximal top layer before the thermoplastic material liquefies.

[0072] This proximal top layer can be an integral part of the second object, such as a covering layer within a "hollow"-like panel, wherein the low-density area at least partially fills the core area, or a covering layer, such as a decorative and / or functional covering layer made of (artificial) leather or any other external covering.

[0073] The proximal top layer can be provided in a next step of the method and can be positioned on the proximal side of the second object in a further step of the method. Specifically, the proximal top layer can be a third object as described below, such as a metal sheet, foil, or a covering layer. However, it can also be, for example, a covering layer or a coating as described above.

[0074] The density of the proximal top layer is generally higher than that of the hypodense area.

[0075] The proximal top layer may be another high-density area.

[0076] The proximal top layer may contribute to any of the density distributions of the second object described above, or may be in addition to such a density distribution.

[0077] In particular, it may be any density distribution of a low-density region and the complement of the density distribution of another region, if present.

[0078] One can envision configurations in which high-density regions are unnecessary. For example, a mechanical pressing force can be applied to cause the distal end to partially penetrate the low-density region in a first step. In a subsequent second step, mechanical oscillations can be applied with an amplitude sufficient to render the thermoplastic material flowable. Furthermore, the mechanical pressing force can be reduced to slow the rate at which the first object penetrates the second object.

[0079] Alternatively or additionally, the proximal top layer or any other layer arranged proximal to the low-density region may cause the thermoplastic material to change temperature when the protrusion is pushed through the layer. The change in temperature is not sufficient to liquefy the thermoplastic material, but it reduces the mechanical compressive force and mechanical stimulation required in the step of applying the mechanical compressive force and mechanical stimulation capable of liquefying the thermoplastic material.

[0080] In embodiments comprising a second body having any density distribution as described above, and optionally a proximal top layer, the distal ends of the first bodies (typically protrusion(s)) at least partially penetrate into the low density region before the thermoplastic material becomes flowable.

[0081] The density distribution may be such that the density of the second object in the low-density region is insufficient to generate a pressure required to liquefy the thermoplastic material. Specifically, the density in the low-density region is insufficient to generate a pressure sufficient to liquefy the thermoplastic material when a mechanical compressive force and mechanical stimulation are applied for less than 15 seconds (s) or less than 10 seconds (e.g., less than 5 seconds or 2 seconds). Specifically, the density is not high enough to generate liquefaction when a mechanical compressive force and mechanical stimulation are applied for 0.1 to 1 second, e.g., 0.1 to 0.5 seconds.

[0082] Alternatively or additionally, the step of applying the mechanical stimulus required to liquefy the thermoplastic material is initiated after passing the distal end of the first object through the low-density zone.

[0083] In an embodiment applicable to any density distribution of the second object and / or the low-density region, the method comprises the step of at least partially compressing the low-density region to generate the critical density required for liquefaction of the thermoplastic material.

[0084] The critical density corresponds to the density at which the critical compressive strength is established.

[0085] The step of at least partially compressing the low-density area may be a sub-step of the step of applying a mechanical pressing force and a mechanical stimulation capable of liquefying the thermoplastic material.

[0086] In particular, the step of at least locally compressing the low-density region to a critical density may precede the step of applying a mechanical stimulus.

[0087] The critical density that needs to be established depends on the target duration of application of the mechanical pressing force and mechanical stimulation after which liquefaction should begin.

[0088] The compression may be global compression and / or local compression.

[0089] The overall compression can be established by compressing the low-density region over a larger area, but not only around the protrusion(s). For example, this can be accomplished through the first object body, in particular through its distal side or through a portion thereof. Specifically, the first object body can at least partially penetrate into the low-density region.

[0090] Alternatively, overall compression may be established in the same manner by employing another object of a first object attached to a second object.

[0091] Local compression may be created by the protrusion(s), for example by displacing portions of the low density region(s) into which the protrusion(s) are forced.

[0092] Experiments have shown that, in particular, non-adhesive materials, such as panels made of fiber materials, exhibit unexpected stress-strain properties when a force (load) is applied locally to such materials. "Local" in this context means that the force (load) is applied to an area of ​​the article formed of the non-adhesive material that is significantly smaller than the corresponding extension of the article.

[0093] The following properties have been found on various articles made from non-stick materials when pressure is applied locally and orthogonally to the article:

[0094] A substantially linear relationship between stress and strain can be observed when strain is applied to the article. The substantially linear relationship forms a first region of linear relationship. The linear relationship between stress and strain within the first region can be approximated by a straight line having a first slope.

[0095] • A transition region, where the stress-strain relationship increases steadily following a first region of linear dependence as the strain increases further.

[0096] A second region in which stress and strain have an approximately linear relationship follows a transition region as strain increases further. The approximately linear relationship between stress and strain in the region can be approximated by a straight line having a second slope, wherein the second slope is greater than the first slope.

[0097] The pressure (load) is generated by a pressure gauge with a range of 4 to 200 mm2 ( mm 2 However, there is no implication that the properties summarized above are limited to this range of relevant surface areas.

[0098] Due to this property, a wide range of non-stick materials are surprisingly suitable for bonding methods that rely on liquefaction of thermoplastic materials by applying mechanical pressing forces and mechanical excitations, especially vibrations. This is because the stress level required for liquefaction of the thermoplastic material, i.e., the critical compressive strength, is reached by the non-stick materials only due to the presence of a linearly dependent second region.

[0099] Thus, the step of compressing the low density region may cause the stress-strain properties of the material to be within the second region of linear dependence.

[0100] The strain value at which the first and second inclined lines in the stress-strain diagram intersect is a characteristic value of the observed stress-strain behavior.

[0101] The step of compressing the low density region may result in the material being compressed to at least the characteristic value.

[0102] Alternatively or additionally, the characteristic value may define a minimum threshold value for application, which means that the mechanical excitation used in the step of applying the mechanical compressive force and the mechanical excitation capable of liquefying the thermoplastic material is activated. In other words, the mechanical excitation may be activated at an applied pressure that causes the characteristic strain value.

[0103] Furthermore, it has been observed that deformation of the panel is largely reversible, as long as the liquefied thermoplastic material that has been pressed into the pores, openings, etc. of the panel does not prevent the panel from returning to its original shape.

[0104] However, there are configurations where deformation of the low density region is irreversible, for example if the energy coupled into the panel is high enough to cause permanent densification.For example, the low density region may comprise fibers that melt during the process.

[0105] Any permanent deformation is beneficial to the bond strength.

[0106] In particular with non-adhesive materials, the critical density may be established only around the protrusion(s), for example by locally increasing the overall density by an amount sufficient to achieve the critical density.

[0107] The region of the second object other than the low-density region and / or the proximal top layer and / or at least a portion of any object to be attached to or attached to the second object (e.g., a third object, a cover layer, or an outer covering) may also be compressed. Thus, these regions and / or objects may contribute to a density distribution that is favorable for liquefaction of the thermoplastic material and is established during the method of bonding the first object to the second object. Specifically, liquefaction may also occur in these regions and / or objects.

[0108] In addition, the distal end of the first object (particularly the protrusion(s)) may include a structure designed and arranged to promote local compression of the second object when the distal end is forced into the second object. Specifically, when the structure is forced into the low-density area, the low-density area is at least partially compressed.

[0109] Forcing the first object into the second object may be accomplished in a further step comprising a movement of the first object relative to the second object, in particular a (partial) penetrating movement. Typically, local compression is an effect of the design and arrangement of the structures and of the relative movement.

[0110] Designing and arranging structures to promote localized compression has, in addition to the effect of locally compressing areas of low density (in other words, locally increasing density), at least one of the following effects:

[0111] When the first object is pushed into the low-density area, the material of the second object (e.g. fibers) is pulled in the distal direction. This can lead to an additional effect of entanglement, especially if the second object comprises fibers.

[0112] • The material of the second object is embedded within the structure and in particular within the protrusion(s). This results in a more even distribution of the load acting on the combined first and second objects in use.

[0113] • The embedding quality is improved if the second body comprises a thermoplastic material to form a weld between the structure or typically the protrusion and the second body and / or to cause a change in the structural properties of the second body. Embodiments comprising a weld are described in more detail below.

[0114] For example, the first body may include at least one barb, for example in the form of a gripping barb and / or a dragging barb. The barb may be significantly smaller than the protrusion or may be of such a size that it contributes to the overall shape of the protrusion. In the latter case, the cross-section of the protrusion in a plane perpendicular to the longitudinal axis of the protrusion (also referred to as the protrusion axis) depends significantly on the shape of the barb and / or may depend on the position of said plane, for example due to the presence of the barb.

[0115] Multiple tips arranged with or without offset along the protrusion axis are other examples designed and arranged to promote localized compression.

[0116] This barb or said structure can generally be arranged to increase the density towards which the penetrating distal end is directed, for example by collecting fibers. In other words: the barb ensures that the density in front of the distal end increases in correlation with the penetration depth of the distal end into the second object.

[0117] Such barbs may also be present in embodiments where the second body comprises an increasing density profile.

[0118] In addition to the compression of the low-density area, a weld can also be formed between the thermoplastic material and the compressed zone surrounding the protrusion(s) by correspondingly choosing the material of the low-density area.

[0119] Embodiments in which welds are formed are described in detail below.For example, the low density regions may include thermoplastic fibers.

[0120] An advantage of embodiments comprising compression of low-density regions is that these regions do not need to have the density required to liquefy the thermoplastic material generally or in specific locations. Rather, the density can be low and / or uniform. As noted above, the desired density or density distribution can be established during the process of bonding the first object to the second object.

[0121] Regardless of the precise density distribution of the second object, the distal end or a portion of the distal end (e.g., at least one of the plurality of protrusions) can penetrate the second object from the proximal end to the distal end. The bonding of the first object to the second object can then be established using an anvil having a proximal side with a recessed depression forming a head. In this embodiment, the method includes positioning the proximal side of the anvil relative to the distal end of the second object so that the penetrating distal end of the second object penetrates the recessed depression forming the head.

[0122] Examples of second objects having, for example, low density areas at the surface and, where appropriate, increasing density in a direction normal to said surface, are panels, insulators, sheathing, outer coverings, trims, carriers, absorbers and trim for vehicles such as cars, trains and airplanes, for example in the luggage compartment, in the vehicle interior or around the cab.

[0123] For example, the second object may include natural or synthetic fibers, such as wool or polyester. These fibers may be embedded in a plastic, particularly a thermoplastic material, with the free ends of the fibers (here, the portions of the fibers not embedded in the plastic) forming a low-density region. The fibers and plastic are arranged so that the density increases continuously from the proximal side and optionally decreases again toward the distal side. However, the fibers and plastic may be arranged so that the density is substantially uniform within the region formed by the free ends of the fibers (i.e., the low-density region) and / or substantially uniform within the region formed by the fibers embedded in the plastic. Specifically, the density may increase substantially in a step-like manner as one approaches the region formed by the fibers embedded in the plastic.

[0124] Another group of second objects comprising a location of increased density in a direction normal to the surface thereof, in particular at or near the near side, are panels, sheathing, outer panels, trims, and load-bearing parts comprising a functional layer attached to the core. For example, the functional layer may be at least one of soft, softened, damping, and restraining, in particular comprising a plurality of openings, holes, movable parts, and / or non-rigid parts.

[0125] Another example is a dashboard that includes a top layer, such as a top layer made of artificial leather, disposed on a foam layer, wherein the foam becomes denser and more rigid as the distance from the top layer increases. This dashboard can be considered an example of a second object that includes a proximal top layer, wherein a low-density region is disposed distally of the proximal top layer.

[0126] In one set of embodiments the first object comprises a connection means element, such as a thread, a thread holder, a locking element or a snap lock.

[0127] In an embodiment, the first object is a connector. Specifically, the first object may form or be the connecting device element.

[0128] In an embodiment, the method further comprises the step of providing a further object comprising an attachment site adapted to be adapted to be connected to the connecting device element, and the step of connecting the combined first and second object to the further object.

[0129] In particular, the further object may be a second object such as a panel, a sheathing, a cladding, a trim, a device to which the carrier has to be mounted.

[0130] The attachment site may be a counterpart of a connection device element comprised or formed by the first object.

[0131] In an embodiment, the method comprises the step of providing another object and the first object comprises a first object body designed to form a connection with the other object. The first object body may be any first object body according to the embodiments described below.

[0132] The other object may be a fixing element, such as a nail, a screw, a rivet, etc.

[0133] The another object may be configured to attach an object different from the first object, the second object, and the another object to the first and / or second object.

[0134] In particular, the further object may be provided to comprise a distal end, such as a tapered distal end, and the connection between the first object body and the further object is formed by the distal end of the further object at least partially penetrating into the first object body.

[0135] The method may include the steps of positioning the distal end of the other object relative to the first object body and applying a mechanical compressive force to at least one of the first object, the second object, or the other object, wherein the mechanical compressive force causes the distal end of the other object to at least partially penetrate the first object body.

[0136] In particular, the further step is performed after the step of ceasing the mechanical actuation and allowing the thermoplastic material to resolidify, that is to say after bonding the first object to the second object.

[0137] For example, the first object can be a reinforcement. After being bonded to the second object, the reinforcement enhances the mechanical stability of the second object. In other words, the first object is designed to partially reinforce the second object, thereby establishing a reliable connection between the first object and the second object.

[0138] Using the first object as a reinforcement is advantageous, in particular, when the density distribution of the second object does not allow for a specific connection, such as a connection based on nails, screws, rivets, etc., and / or when the mechanical stability of the second object makes various connection methods unsuitable for a reliable connection, for example, because the second object is bendable. Connections based on nails, screws, rivets, and adhesive-based methods are examples of methods that do not result in a reliable connection between the first object and the second object, for example, if the second object is bendable.

[0139] Additionally or alternatively, the connection between the first object body and the second object may be formed by the first object body comprising connection device elements as described above and the other object comprising associated corresponding elements.

[0140] An important advantage of connecting and / or attaching an object different from the first and second objects to a second object by using the first object as a connection site (i.e., by using a two-step method) is that the objects can be moved again. This statement is indeed independent of the specific implementation of the connection and / or attachment. In particular, the first object can include a connection device element or the first object body can be designed to form the connection.

[0141] In an embodiment, the first object includes a proximal side, a distal side, and a connection portion. The connection portion includes at least a portion of the proximal side of the first object body. For example, the connection portion or a portion thereof extends from the proximal side portion as a protrusion, or the connection portion or a portion thereof is an opening in the first object body, wherein the proximal side portion forms a mouth of the opening.

[0142] In this embodiment, the first object includes a protrusion area arranged at the distal side of the first object body, in particular the protrusion area in any one of the embodiments described below, and includes a functional area without any protrusions, in particular the functional area in any one of the embodiments described below, wherein the functional area is opposite to the proximal side portion included by the connection part.

[0143] In an embodiment, the mechanical pressing force and the mechanical excitation are applied locally to at least one of the first object and the second object. In other words, the first object is bonded to the second object at separate bonding locations, i.e., the bond is established by using bonding points rather than using a continuously extending bonding area.

[0144] For example, the joining portion can be circular, oval, rectangular, or square, and have a characteristic length that is significantly smaller than the characteristic extension, at which the first and second objects are joined. Specifically, this characteristic length lies between a few millimeters and a few centimeters, for example, between 1 millimeter (mm) and 10 centimeters (cm), in particular between 1 mm and 5 cm, such as 0.5 mm, 1 cm, 2 cm, 3 cm, 4 cm, or 5 cm. However, cases are conceivable where a characteristic length greater than 10 cm is required, for example, if the first object forms a closed or partially closed form with the central opening.

[0145] In this embodiment, the steps of applying a mechanical compressive force and mechanical stimulation and the steps of ceasing the mechanical stimulation and allowing the thermoplastic material to resolidify are repeated multiple times at different locations on at least one of the first object or the second object.

[0146] An advantage of this embodiment is that there is no restriction on the shapes of the first and second objects, as long as they can be arranged to form an assembly of the first and second objects including the joining locations and as long as these locations are penetrable for tools for applying mechanical pressing forces and mechanical excitation.

[0147] In particular, the first and / or second objects need not be substantially flat. Rather, one or both of the objects may be curved. Furthermore, there are no restrictions on the positioning of the joints relative to one another. For example, the joints need not be arranged on a plane or on planes extending parallel to one another.

[0148] Examples of tools equipped for applying mechanical pressing forces and mechanical excitation are handheld welding poles or welding poles mounted on a robot arm.

[0149] The steps of applying mechanical pressing force and mechanical stimulation and stopping mechanical stimulation and allowing the thermoplastic material to resolidify are repeated a number of times depending on various parameters such as the shape and material of the first and second objects and the desired bonding strength.

[0150] In an embodiment, the axis along which the mechanical oscillation occurs is substantially perpendicular to the proximal surface.

[0151] With the bond separated, the axis along which the mechanical oscillation occurs is substantially perpendicular to the portion defining the proximal side of the bond.

[0152] The proximal end of the first object may include a coupling-in surface configured to receive a mechanical compressive force and a mechanical excitation. After the step of arranging the first object relative to the second object to form an assembly of the first and second objects, the coupling-in surface may be arranged parallel to the proximal side surface or a portion of the proximal side surface defining the bonding site.

[0153] In an embodiment, the provided first object comprises a coupling-in surface, and the method further comprises the steps of providing a soldering electrode comprising an output surface conforming to the coupling-in surface and bringing the output surface into contact with the coupling-in surface before the step of applying the mechanical pressing force.

[0154] Alternatively, the second object, in particular the distal side of the second object, may comprise the coupling-in surface. In other words: the mechanical pressing force and the mechanical excitation required for liquefying the thermoplastic material may be applied to the distal side of the second object.

[0155] In an embodiment, the first object, the second object and the welding electrode are arranged relative to each other such that the second object is located between the first object and the welding electrode and such that the proximal side of the second object is in contact with or comes into contact with at least one protrusion of the first object during the method.

[0156] For example, the first object may be formed from a component of a vehicle body, with at least one protrusion comprising a thermoplastic material disposed on the vehicle body component. The second object may be a cover. The shape of the cover may conform to the shape of the vehicle body and / or the structure of the first object(s). According to this exemplary embodiment, the second object is positioned above the first object, and the welding electrode is applied to a surface area of ​​the second object opposite to the surface area of ​​the second object that is in contact with the protrusion.

[0157] Mechanical compressive force and mechanical stimulation can be applied to the distal surface of the second object using the welding electrode. In this embodiment of the method, the distal surface of the second object is the exposed surface that is "proximal" to the user operating the welding electrode due to the fact that the surface of the object is defined relative to the center origin of the first object.

[0158] In embodiments where the electrode is applied to the second object, the method may include a step of compressing the second object, such as compressing the low-density region. Specifically, the compression may enable the second object to transmit the mechanical stimulus applied to the distal surface of the second object.

[0159] The unexpected stress-strain properties discussed above make a wide range of non-viscous materials suitable for transmitting mechanical excitations used in bonding methods that rely on the liquefaction of thermoplastic materials by applying mechanical compressive forces and mechanical excitations, particularly vibrations. Furthermore, the existence of a second region of linear dependence is attributed only to the fact that a wide range of non-viscous materials achieve the stress levels required to transmit the mechanical excitations.

[0160] Thus, the step of compressing the low density region may cause the stress-strain properties of the material to lie within a second region of linear dependence and / or cause the material to be compressed to a characteristic strain value given by the oblique intersection of the first and second bodies.

[0161] In an embodiment in which the welding electrode is applied to the first object, the steps of applying mechanical pressing force and mechanical excitation to the first / second object can be accomplished by the welding electrode being pressed against the coupling-out surface of the first object, while the second object can be optionally supported directly or indirectly by a support member (the support member can be directly supported against the second object at a lateral position of the action of the welding electrode, or it can be composed of a frame of a more complex object supporting the second object; this complex frame can be, for example, the body of the object to be mounted, such as a car body).

[0162] Optionally, the method may further comprise the step of locking the first object to the welding electrode after the step of bringing the out-coupling surface into contact with the in-coupling surface.

[0163] The distal end of the welding electrode including the coupling-out surface may include an opening and a recess so that proximal protrusions of the first object are not affected by the use of the welding electrode.

[0164] The mentioned connecting means elements are examples of possible proximal protrusions of the first object.

[0165] The welding electrode may be a ring-shaped welding electrode.

[0166] The distal end of the welding electrode, in particular the coupling-out surface, and the extension of the first object, in particular the extension of the first object at its distal end (eg the coupling-in surface), can be such that the distal end of the welding electrode covers at least the proximal end of the first object during the joining process.

[0167] However, it is also possible that the distal end of the weld and the extension of the first object are such that the mechanical pressing force and the mechanical oscillations applied to the first object by the welding electrode are only local.

[0168] It is conceivable that a plurality of joints can be simultaneously subjected to mechanical pressing forces and mechanical excitations. For example, this can be accomplished by a welding electrode comprising a distal coupling surface that is adapted to the joint to be established.

[0169] In an embodiment, a first object is provided comprising a raised region distal to a main body of the first object, wherein the first body comprises a distal side and wherein the raised region comprises a plurality of protrusions comprising a thermoplastic material.

[0170] It is conceivable that not all protrusions (but for example a plurality of protrusions) comprise a protruding portion after the step of ceasing the mechanical actuation and allowing the thermoplastic material to resolidify.

[0171] Each protrusion comprises an extension in the distal direction and a thickness.For example, the extension in the distal direction is the length of the protrusion if the longitudinal protrusion axis extends along an axis perpendicular to the distal face.

[0172] The extension of the protrusions in the distal direction may be different among the plurality of protrusions included in the protrusion zone.

[0173] Specifically, the first object may include at least one first-type protrusion comprising a thermoplastic material and at least one second-type protrusion comprising a thermoplastic material, wherein the first-type protrusion has a greater distal extension than the corresponding distal extension of the second-type protrusion. Thus, the form-fit connection established by the first-type protrusion and the form-fit connection established by the second-type protrusion are located at different distal locations.

[0174] Embodiments comprising the first and second types of protrusions (and, as appropriate, other types of protrusions having a distal extension that differs from the distal extensions of the first and second types of protrusions and from each other) may include at least one of the following:

[0175] • The extent of the protrusion in the distal direction may be selected such that the bond of the first object to the second object is formed by involving the second object having a larger volume than a bond based on an extension having the same extent in the distal direction.

[0176] • The protrusions with a large or greater extension in distal direction and the protrusions with a small or smaller extension in distal direction are arranged such that subsequent processing steps of the article, such as forming steps including a first object being joined to a second object, are feasible.

[0177] • The protrusions with a large or greater extension in the distal direction and the protrusions with a small or smaller extension in the distal direction are arranged such that the bending strength and / or the tensile strength is optimized.

[0178] For example, protrusions with a large extension may be arranged on the distal surface adjacent to one or more lateral edges of the first object body, wherein protrusions with a smaller extension may be arranged in a central position on the distal surface of the first object body.

[0179] • Selective combination of protrusions with different extensions in the distal direction that are optimized with regard to material costs and protrusion structures with different extensions in the distal direction that are optimized for a specific application and the tensile / bending forces achieved by said application.

[0180] Regardless of the specific embodiment of the method or apparatus (here, the first object), the protruding portion corresponds to the associated protrusion after the protrusion has been deformed during the step of stopping the mechanical actuation and allowing the thermoplastic material to resolidify. Thus, it is located within the region of the initial protrusion relative to the main body of the first object. Specifically, before the application of the mechanical compressive force and mechanical actuation, the protruding portion extends from the distal surface of the first object at the same location as the protrusion.

[0181] For example, the protrusion may be a portion of the protrusion that does not liquefy during the steps of applying the mechanical compressing force and mechanically stimulating. However, the protrusion may also be an accumulation of resolidified material in an area opposite the first object, where the protrusion existed before the steps of applying the mechanical compressing force and mechanically stimulating.

[0182] After the mechanical actuation is stopped and the thermoplastic material has resolidified, the protrusion(s) have the effect of extending into the bonding zone of the second object, meaning that the bonding zone is not limited to the surface area of ​​the second object. In other words, a deep-seated anchoring is established. This significantly increases the mechanical strength of the bond, in particular its mechanical load-bearing capacity, compared to a bond without protrusions.

[0183] The protrusion(s) used in embodiments of the present invention are not energy directors as described below. For example, the protrusion(s) are dimensioned along an axis perpendicular to the distal side of the first body of the object so that they allow for deep-affected anchoring. This means that their extension along the axis perpendicular to the distal side is greater than the corresponding extension of the energy director. In addition, the protrusion(s) may form a projection after the step of stopping the mechanical excitation and allowing the thermoplastic material to resolidify. The energy directors do not form such a projection because they define the location where liquefaction begins, which also means that they are dispersed during the steps of applying the mechanical pressing force and mechanical excitation.

[0184] However, the protrusion(s) may comprise energy directors.

[0185] The protrusion(s) may be tapered and have any pointed and / or sharp form, such as, for example, a ridge or a point.

[0186] The protrusion(s) may also decrease in size in a step-wise manner or they may be of constant size.

[0187] The protrusions, some or all of the protrusions may include structure designed and arranged to promote the localized compression described above.

[0188] The protrusion or at least one of the protrusions may be symmetrical in shape. In particular, it may have a shape that is not rotationally symmetrical about an axis perpendicular to the distal side of the first object body.

[0189] In an embodiment, the protrusion or at least one of the protrusions is at least one of the following:

[0190] • Assembling for defining the deformation direction during the steps of applying mechanical pressing force and mechanical excitation.

[0191] For example, the protrusion may include grooves arranged such that the protrusion deforms in a particular direction when loaded and / or the protrusion may be bent away from an axis perpendicular to the distal surface of the first object body prior to the steps of applying the mechanical compressive force and mechanical actuation.

[0192] equipped to define the direction in which the liquefied thermoplastic material flows during the steps of applying the mechanical pressing force and the mechanical actuation, and

[0193] • comprising a projection axis extending at an angle relative to the distal side of the first object body, wherein the angle is not a right angle.

[0194] Each protrusion comprises an extension in the distal direction and a thickness as described above.If the longitudinal protrusion axis extends along an axis perpendicular to the distal face, then the extension in the distal direction is the length of the protrusion.

[0195] In an embodiment, the ratio of the extension in the distal direction to the thickness is at least 1, in particular between 1 and 5, for example between 1.5 and 4 or between 2 and 3. In other words: the extension of the protrusion(s) along an axis perpendicular to the distal side is greater than the thickness in a direction radial to said perpendicular axis.

[0196] In an embodiment, the extension of the protrusion(s) in the distal direction corresponds to 10%-80% of the corresponding thickness of the second object or, depending on the specific implementation of the second object, corresponds to 10%-80% of the corresponding thickness of the low-density region. Specifically, the extension of the protrusion(s) in the distal direction corresponds to 15%-70% or 20%-50% of the corresponding thickness.

[0197] In embodiments comprising a plurality of protrusions, the protrusion region comprises gaps between the protrusions.

[0198] As used herein, "gap" refers to the total space that separates one protrusion from the other protrusions, not the distance between the protrusions.

[0199] The gap may extend to the distal side of the first object body. Specifically, the protrusions may be arranged on the distal side of the first object body in such a manner that a flat area of ​​the distal side is formed between the protrusions.

[0200] The flat area may form a stop surface as described below.

[0201] As described above, the surface of the first object defining the gap may be arranged to compress the first object, in particular the low density regions, prior to liquefying the thermoplastic material.

[0202] In particular, the surfaces are arranged to create an overall compression and an applied local compression, wherein the local compression is generated around the protrusions and ensures the critical compression required for the liquefaction of the thermoplastic material.

[0203] Furthermore, the surface stabilizes the bonding process due to the fact that a steadily increasing reaction force is formed against the applied mechanical pressing force. This also helps to avoid undesired penetration of the second object or low-density areas and compensates for density variations within the second object or low-density areas.

[0204] The total volume of the protrusion region can be given by the portion of the distal side of the first object body comprising the protrusions and the extension of the protrusion region in the distal direction. For example, the extension of the protrusion region in the distal direction can be the extension of the protrusions along an axis perpendicular to the distal side, wherein all protrusions have the same extension, and the portion of the distal side comprising the protrusions forms the base of the protrusion region, so that the total volume of the protrusion is given by the product between the distal side and the portion and the extension.

[0205] In an embodiment, the total volume is comprised of the volume of the plurality of protrusions and the volume of the gaps within the protrusion region (this represents the total volume of the spaces mentioned above), wherein the volume of the gaps is greater than the volume of the gaps. In other words, the ratio of the volume of the gaps to the volume of the protrusions is greater than 1, particularly greater than 2, for example, 3, 4, or 5. In many embodiments, the ratio is less than 10.

[0206] In an embodiment, the distal side of the first object body comprises a functional area, which means an area having a function other than combining the first object and the second object. Thus, the functional area does not include any protrusions.

[0207] This functional area is not located at all in the joint that contacts with the near side of the second object or is only located at the end of this joint.Thus, its mechanical and / or thermal load is significantly reduced compared with the region that comprises protrusion of the far side of the first object main body.

[0208] For example, the functional area comprises a distal port of an opening through the body of the first object. The opening may be a guide for a wire or a sensor and / or it may form the end of an opening in the second object, for example.

[0209] In an embodiment, the protrusions may consist of a thermoplastic material or the thermoplastic material may be arranged at least partially around a core of a harder material. In this context, a harder material means a material that does not become flowable due to an applied mechanical pressing force and mechanical stimulation.

[0210] The hard material may be, for example, a plastic material other than a thermoplastic material or a metallic material.

[0211] In particular, after the first object is so arranged relative to the second object, the portion of the tips or ridges of the protrusion(s) that come into contact with the second object may be made of a harder material that is not covered by the thermoplastic material.

[0212] Alternatively, the distal end, step and edge of at least one of the protrusions may comprise thermoplastic material. In this embodiment, the protrusions form so-called energy directors by their shape. This means that they define one or more locations where the thermoplastic material begins to liquefy.

[0213] Energy directors are structures at which applied mechanical oscillations and / or pressure are focused and coupled into the thermoplastic material in an efficient manner.

[0214] The first object in any embodiment may comprise an energy director other than that which may be formed by, for example, tapered, stepped or pointed protrusions, such as other tips and ridges arranged on the sides of the protrusions.

[0215] In embodiments where the provided first object comprises a protrusion at its distal end, the method may comprise the step of positioning the first object relative to the second object such that the protrusion is in physical contact with the proximal side.

[0216] Additionally, the step of applying the mechanical pressing force may include applying a mechanical pressing force strong enough to cause the protrusions to pass through the low-density region and other regions selectively arranged proximal to the low-density region.

[0217] The effect of the extended low density area before applying pressure suitable for liquefaction of the thermoplastic material and / or before applying mechanical oscillations is to extend into the bonding area of ​​the second object, ie the bonding area is not limited to the surface area of ​​the second object.

[0218] This effect can be further enhanced by applying strong mechanical pressing forces so that the protrusions penetrate into areas of high density.

[0219] Specifically, the step of applying the mechanical pressing force includes applying a first mechanical pressing force and a second mechanical pressing force, wherein the first mechanical pressing force is less than or equal to the second mechanical pressing force.

[0220] For example, the first mechanical pressing force has an intensity such that the distal end (eg, protrusion) of the first object penetrates a low-density region of the second object, while the second mechanical pressing force has an intensity such that the distal end (eg, protrusion) of the first object penetrates a higher-density region.

[0221] The second mechanical pressing force can be adjusted, for example in terms of penetration speed, to ensure precisely controlled penetration into the region with a higher density.

[0222] Typically, the second object mechanical pressing force is initiated prior to the mechanical actuation capable of liquefying the thermoplastic material.

[0223] The increase from the first mechanical pressing force to the second mechanical pressing force may be continuous or stepwise.

[0224] In one embodiment, the method further comprises the following steps:

[0225] Providing a third object comprising a third-object proximal side and a third-object distal side.

[0226] positioning a third object relative to the second object such that a distal surface of the third object is in physical contact with a proximal surface of the second object;

[0227] Prior to the step of applying a mechanical stimulus capable of liquefying the thermoplastic material and causing the flowable portion of the thermoplastic material to penetrate the structure of the second object, forcing at least a portion of the first object through the third object from the proximal side of the third object to the distal side of the third object.

[0228] However, another insight of the present invention is that both (multiple) protrusions comprising a solid thermoplastic material and (multiple) protrusions consisting of a thermoplastic material can be used to pierce third objects of various materials and sizes by optimizing the mechanical pressing force, mechanical excitation and the start time of the mechanical excitation relative to the mechanical pressing force.

[0229] In an embodiment, the third object may include or consist of a sheet material without pre-drilled holes, and the method may include the step of piercing the sheet material before applying the mechanical compressive force and mechanical stimulation capable of liquefying the thermoplastic material. However, this does not necessarily mean that the mechanical compressive force and / or mechanical stimulation are applied during the step of piercing the metal sheet.

[0230] The pierced sheet may be a flange arranged to secure the third object to the second object.

[0231] The sheet may be arranged relative to the first and second objects such that the first protrusions of the first object pierce the sheet prior to joining the first object to the second object and such that the second protrusions do not contact the sheet during the method.

[0232] In particular, the sheet material may be a metal sheet.

[0233] Experiments have shown that it is possible to pierce at least titanium sheets with a thickness (strength) of up to 0.3 mm and aluminum sheets with a thickness of up to 0.5 mm.

[0234] In embodiments where a third body is provided or not, the method may comprise the step of using a mechanical actuation to modulate the penetration behavior of the protrusion(s).

[0235] If the mechanical excitation is used in combination with a pressure acting on the thermoplastic material which is not capable of liquefying the thermoplastic material, the penetration depth of the protrusion(s) into the second object can be adjusted.

[0236] If the mechanical excitation is combined with pressure acting on the thermoplastic material to liquefy it, the thermoplastic material can be liquefied in a continuous manner and pressed into the second object. This can form layered regions within the second object or head-like structures on the distal side of the second object, thereby forming a more reliable bond.

[0237] Additionally, the method according to this embodiment may include the step of locally and / or globally compressing portions of the second object to achieve a critical density required for liquefaction of the thermoplastic material.

[0238] In an embodiment, the first object includes at least one first-type protrusion comprising a thermoplastic material and at least one second-type protrusion comprising a thermoplastic material. During the step of applying a mechanical compressive force and a mechanical stimulus capable of liquefying the thermoplastic material, the first-type protrusion is shaped such that a flowable portion of the thermoplastic material penetrates into the structure of the second object, and the second-type protrusion is shaped such that the flowable portion of the thermoplastic material penetrates into the structure of the third object.

[0239] For example, the dimensions (particularly length and thickness) of the first and second protrusions may be adapted to each other and to the thickness of the second and third objects so that their liquefaction starts at desired locations within the second and third objects, respectively.

[0240] In particular, the third object may have the same density distribution as the second object. In this case, the length of the first type of protrusions and the length of the second type of protrusions may be adapted to the distance of the low-density area from the near side of the third object.

[0241] The depth of the bonding area within the second object may be adjusted by the duration of the mechanical pressing force applied prior to applying the mechanical excitation and / or the intensity of the mechanical pressing force.

[0242] The provided first object may include indicia indicating the penetration depth of the first object into the second object prior to the step of applying a mechanical compressive force and a mechanical stimulation capable of liquefying the thermoplastic material.

[0243] The depth of the bonded area in the second body corresponds to the maximum penetration depth of the thermoplastic material of the first body into the second body after resolidification, the maximum penetration depth being measured along the axis along which the first body is forced into the second body.

[0244] Typically, the maximum penetration depth is measured along an axis normal to the proximal side of the second object, or, as the case may be, along an axis normal to the portion of the proximal side defining the bonding site.

[0245] In an embodiment, the step of applying the mechanical pressing force may be performed until the abutting surface portions of the first object and the second object (or the first and second objects as the case may be) abut against each other.

[0246] Specifically, a first object is provided that includes a stop surface. For example, the stop surface is a surface arranged to lie flat on the second (third) object after the first object is joined to the second object.

[0247] This stop surface may define a maximum penetration depth of the thermoplastic material of the first body into the second body.

[0248] If the first object includes a protrusion, the protrusion extends from a distal side of the stop surface.

[0249] If the first object comprises a marking which indicates the penetration depth of the first object into the second object before the first object liquefies, the stop surface is arranged proximally of the marking.

[0250] In cases where the second object comprises a distal side which must not be affected by the method of bonding the first object to the second object, measures which result in a well-defined depth of the bonding area are advantageous.

[0251] Decorative layers, so-called "A-surfaces" or any other surface visible to the user after bonding are examples of surfaces that must be unaffected by the bonding method.

[0252] In an embodiment, the method further comprises the steps of providing a third object comprising a third object proximal side and a third object distal side, arranging the third object relative to the second object such that at least a portion of the third object distal side is in physical contact with the second object proximal side, and forcing at least a portion of the protrusion through the third object from the proximal side of the third object to the distal side of the third object.

[0253] In this embodiment, the third object is specifically at least one of the following:

[0254] A metal sheet comprising a through hole that forms a region that is curved in the distal direction.

[0255] The curved region may cause a local compression of the second object during the step of pressing the curved region into the second object.

[0256] The through-hole is designed such that after the first object is joined to the second object, a protruding portion is present in the second object, which means that after the third object is attached to the second object by joining the first object to the second object, the protrusion can also lead to (if appropriate) local compression of the second object in the region of the opening.

[0257] The method may include the steps of applying a compressive force to a portion of the protrusion and forming a melt zone at a contact surface between the portion of the protrusion and the third object.

[0258] For example, the curved region can be elastically deformed and the diameter of the through hole forming the curved region is smaller than the diameter of the protrusion. Thus, the elastically deformable curved region can be deformed by pushing the protrusion through the opening. This deformation can generate a lateral compressive force applied to the portion of the protrusion.

[0259] A foil, wherein the foil is designed to be penetrated by a projection. In particular, it can be provided as a perforated foil. Alternatively, the thickness and strength of the foil are such that it can be penetrated by a projection in the method.

[0260] Optionally, the foil may comprise or be made of a thermoplastic material to form a weld bond between the foil and the protrusions.

[0261] One could conceivably provide a third object which is not a foil, but which can nevertheless be penetrated by the projections and / or comprises a thermoplastic material.

[0262] The third body comprises a thickness and density distribution such that the protrusions can penetrate the third body during the step of applying the mechanical pressing force and the mechanical actuation without causing the thermoplastic material of the protrusions to liquefy inside or at the surface of the third body.

[0263] In another embodiment of the method including the further step of providing a third object, the first object provided includes a first object body having a proximal side of the first object body, the third object provided includes a third object proximal side and a third object distal side, and the method includes the further step of arranging the third object relative to the first object so that the third object distal side is in physical contact with the proximal side of the first object body.

[0264] Optionally, the third object may be arranged and fixed to the first object such that the third object is not in direct contact with the second object.

[0265] The third object may be glued to the proximal side of the main body of the first object.

[0266] In embodiments, the provided second object includes a distal surface, and the provided first object and the steps of applying the mechanical compressive force and the mechanical stimulation are such that the distal surface is not affected by the method.

[0267] Specifically, a mechanical excitation can be applied to the distal surface of the first object, and a force can be applied to the first object to drive at least one protrusion into the low-density region. This arrangement of mechanical excitation and force to drive the protrusion(s) into the second object can be used to create a density distribution in the low-density region in which maximum densification is formed at the distal ends of the protrusions rather than at the distal surface of the second object.

[0268] The distal side of the second object may be the distal side of the low-density region. For example, the second object is composed of a low-density region at least at the location where the first object is to be bonded to the second object.

[0269] The force used to drive the at least one protrusion into the low-density region may be or cause the mechanical pressing force required to liquefy the thermoplastic material.

[0270] In particular, the depth of the bonding area is less than the thickness of the second object, the thickness of the second object being defined as the distance between the proximal side and the distal side of the second object, wherein any compression effects causing the thickness of the second object to decrease during bonding of the first object to the second object are taken into account.

[0271] However, this does not mean that the protrusion has a length that is less than the thickness of the second object. In other words, the length of the protrusion along the axis along which the first object is forced into the second object is greater than the thickness of the second object. This is because the thermoplastic material penetrates the structure of the second object and thus in a direction different from the axis.

[0272] In embodiments where the distal side of the second object is formed from a layer different from the proximal side and / or the core layer, the depth of the bonding region may be such that the bonding region does not contact the layer forming the distal side. Specifically, the method of bonding the first object to the second object does not rely on any physical properties of the layers.

[0273] The stop surface, markings, duration of mechanical compressive force applied prior to mechanical stimulation, and any combination thereof described above are examples of a first object and embodiments of a method adapted so that the distal surface is not affected by binding.

[0274] The use of mechanical oscillations having an amplitude insufficient to cause liquefaction of the thermoplastic material in combination with a mechanical pressing force for forcing the first object into the second object can help reduce at least one of the mechanical pressing force for forcing the first object into the second object, the mechanical load on the distal surface, the stress introduced into the second object, and the stress on the distal surface of the second object.

[0275] In an embodiment, the provided second object comprises a thermoplastic material capable of liquefying when subjected to mechanical compressive forces and mechanical oscillations, as applied in the method. The step of applying the mechanical stimulus may then include at least partial liquefaction of the thermoplastic material of the second object to form a weld between the liquefied thermoplastic material of the second object and the liquefied thermoplastic material of the first object after the thermoplastic materials resolidify.

[0276] The meltability of the second object may cause the structure of the second object to change.

[0277] For example, the second object may comprise thermoplastic fibers, such as those described above. Subsequently, the thermoplastic fibers may melt together in the region surrounding the protrusion(s) due to the applied mechanical pressing force and the impact of the mechanical excitation. In other words: the thermoplastic fibers are connected in said region.

[0278] This structural change of the second object strengthens (especially strengthens and hardens) the joint between the first object and the second object. In other words: the quality of the bond between the first object and the second object can be improved by the composition of the second object, especially by the composition of the low-density region.

[0279] In order to facilitate the structural change of the second object, at least one of the following features may be advantageous:

[0280] • A high concentration of thermoplastic material, such as thermoplastic fibers, in the area of ​​the second body which becomes the bonding site.

[0281] • The melting point of the thermoplastic material of the second object is similar to or lower than the melting point of the thermoplastic material of the first object.

[0282] This weld may also be formed in the third body.

[0283] In embodiments where the second body comprises, for example, natural or synthetic fibers embedded in plastic, the plastic may be the thermoplastic material of the second body.

[0284] For example, the second object may be prepared by a method comprising the steps of:

[0285] Providing a first type of fiber and a second type of fiber, wherein the first type of fiber has a melting temperature lower than the melting temperature of the second type of fiber.

[0286] • Combining the first type of fibers and the second type of fibers to form a combination of the first type of fibers and the second type of fibers.

[0287] Heating the first and second fibers to a temperature at which the first fibers are at least partially melted and have embedded therein unmelted second fibers.

[0288] In embodiments of the method in which a weld is formed between a first and a second object, the weld can be formed between the thermoplastic material of the first object and the first type of fibers (flowing together), between the thermoplastic material of the first object and the second type of fibers, or between the thermoplastic material of the first object and the first type of fibers and the second type of fibers.

[0289] Which parts the weld forms between and where in the assembly of the first and second objects the weld forms depends on the physical properties of the parts (particularly melting temperatures and compatibility) and the shape and relative arrangement of the first and second objects.

[0290] In an embodiment, the first type of fibers comprises or consists of polypropylene.

[0291] The first object may be, for example, a glass fiber reinforced plastic (eg polypropylene) connector.

[0292] If the first object is a glass fiber reinforced plastic (e.g. polypropylene) connector and the first type of fiber consists of the same plastic (e.g. polypropylene), the welding location can be arranged by defining the location of highest heating, for example by the shape of the coupling-out surface, the shape of the coupling-in surface and / or by using energy directors.

[0293] The weld may be formed by infiltration of the liquefied thermoplastic material of the first body into the structure of the second body.

[0294] In an embodiment, the second object is placed in a mold that conforms to the desired shape of the second object. The steps of applying mechanical compressive force and mechanical actuation can be performed on the second object supported by the mold. This can prevent deformation of the distal surface of the second object due to the pressure applied during the bonding process of the first object to the second object.

[0295] The present invention also relates to a device adapted to be attached to an article by the method of any embodiment, whereby the device corresponds to a first object and the article corresponds to a second object.

[0296] The device may include any of the features disclosed in relation to the first object.

[0297] The device extends between a proximal end and a distal end and includes a device body defining a proximal side and a distal side. The device includes a plurality of protrusions extending from the distal side.

[0298] The device also includes a thermoplastic material in a solid state. Specifically, the protrusion includes a thermoplastic material at its outer surface.

[0299] The protrusion may comprise a core of a harder material as described above, with the thermoplastic material arranged around the core.

[0300] Alternatively, the protrusion, the protrusion and the device body or the device are constructed from a thermoplastic material.

[0301] Each protrusion may taper towards one or more points, ie a tip or multiple tips, or may taper towards a line, ie a ridge, where the line may be straight or curved.

[0302] The protrusion may be continuously narrowed or in a step-like manner.

[0303] The protrusions may form energy directing structures by their overall shape (eg by being tapered or by comprising steps) and / or they may comprise structures specifically acting as energy directors.

[0304] In an embodiment, the device comprises a stop surface formed by a portion of the distal surface that is free of the support protrusion.

[0305] In particular, the protrusion extends substantially orthogonally to the distal side, so that the stop surface extends substantially perpendicular to the axis along which the protrusion extends, for example, in a conical shape.

[0306] Specifically, the stop surface is formed by the portion of the distal side between the projections. However, it is also conceivable that the projections are arranged so that one projection is in direct contact with its adjacent (multiple) projections. In this embodiment, the stop surface is reduced to a line extending between the projections.

[0307] In an embodiment, the device is a connector. For example, the device further comprises a connecting device element and / or the body of the device is such that another object can be attached (eg, coupled or anchored) within the body of the device.

[0308] Said elements may be mechanical and / or electrical connection elements.

[0309] Specifically, the connector may be configured to attach another object to a proximal end of the connector, wherein the connector is coupled to the object at its distal end.

[0310] For example, an element of the connector is arranged on the proximal side so that a corresponding element of a connection mechanism arranged on another object can engage with the element of the connector.

[0311] The connector may include proximal functional structures, which are herein referred to as functional structures disposed on or within the proximal side of the device body.

[0312] The proximal functional structure may be a connecting structure which defines the connection site, in particular the connection site with reference to all dimensions (x, y, z).

[0313] The functional structure (connection part, if the functional structure is a connection part) can be eccentric with respect to the insertion axis, so that the orientation of the connector about its insertion axis (usually a proximal-distal axis centered with respect to the device body and / or the protruding area) determines the position and orientation of the connection part. In this context, the functional structure is distinguished from, for example, a coaxial fastening hole (with or without threads), a coaxial pin, or a proximally projecting threaded rod, head, etc., or any other conventional fastening structure of known fasteners.

[0314] The method may include engaging the connector at a well-defined x, y, and z position and in a well-defined orientation relative to the second object.

[0315] As a result, one or more of the following measures may be taken:

[0316] - The means by means of which the mechanical pressing force and, where appropriate, the mechanical excitation are applied comprise a position controller which stops the process when the connector has reached a well-defined z-position.

[0317] ‐The connector has a stop surface, here a distal abutment surface, which stops the process under the following conditions: the stop surface abuts against the proximal side of the second object or a corresponding proximal structure of the second object, or the mechanical resistance to further forward movement of the connector toward the second object has reached a certain value (force control), or the proximal side of the device body (or a part of the device body) is flush with a part of the proximal side of the second object.

[0318] - The connector has a non-rotationally symmetric (about the insertion axis) guide structure that cooperates with a corresponding structure of the tool to define the orientation.

[0319] The coupling input face of the connector may comprise or form a guide structure.

[0320] The tool, in particular the coupling-in surface of the weld, can include or form a corresponding structure.

[0321] - The connector has a distal guide structure which is rotationally asymmetric about the insertion axis and which cooperates with a corresponding rotationally asymmetric positioning hole of the second object.

[0322] More generally, the functional structure may be a portion of the functional portion that also includes a distally directed abutment structure, wherein the mechanical compressive force or mechanical compressive force is applied until the abutment structure abuts against the proximal side of the second object or a portion of the proximal side. This abutment structure may be the distal side of the plate-like device body, or it may be formed by another feature of the functional portion. The abutment portion defines a separation plane between the distal protrusion(s) and the proximal functional portion.

[0323] In particular, the connector may include a proximal functional mechanism in combination with a protruding region including a plurality of protrusions (here representing a plurality of separate coupling sites).

[0324] In an embodiment, the device, or more generally the first object, may comprise a cutting structure. In particular, the protrusion(s) may be formed to comprise a cutting structure.

[0325] The device (first object) used in any of the embodiments of the method described above includes natural oscillations. When the mechanical excitation used to liquefy the thermoplastic material is a mechanical oscillation having a frequency that allows the excitation of natural oscillations, these natural oscillations can adversely affect the device, particularly the device body (first object body). In other words, destructive natural oscillations can be induced in the device.

[0326] In an embodiment of the device (respectively of the first object), the device comprises features capable of avoiding or damping destructive natural oscillations. For example, the device comprises at least one of the following:

[0327] A damping element arranged at the distal side of the device body. Specifically, the damping element is designed to come into contact with the second object or the third object during the method.

[0328] A fixing element comprising a fixing element connection mechanism and a connecting element comprising a connecting element connection mechanism, the fixing element connection mechanism and the connecting element connection mechanism being adapted to each other in such a way that the connecting element connection mechanism is rigidly connected to the fixing element connection mechanism at least when the fixing element is fixed to the object.

[0329] The method comprising the steps of providing a first object having a fixing element and a connecting element may include a second step of applying a mechanical pressing force and a mechanical actuation after the step of applying a mechanical pressing force and a mechanical actuation for forming a positive connection between the first object and the second object. In this case, a positive connection is formed between the fixing element and the connecting element. The second step of applying a mechanical pressing force and a mechanical actuation forms a bond between the fixing element and the connecting element, in particular by using a fixing element connecting mechanism and a connecting element connecting mechanism.

[0330] The fixing element and the connecting element can be designed such that no destructive natural oscillations are excited in the connecting element during the second step of applying the mechanical pressing force and mechanical excitation.

[0331] However, one can also envisage other means for joining the connecting element to the fixing element which do not comprise thermoplastic material, such as a snap lock, a snap lock, a clamping mechanism.

[0332] • Multiple raised areas separated from each other.

[0333] It has been discovered that the frequency of the natural oscillation of the device body (first body) can be adjusted to deviate from the frequency of the mechanical excitation required and applied to cause liquefaction of the thermoplastic material by disposing a plurality of different raised areas on the distal side of the first body. Specifically, the frequency of the natural oscillation can be adjusted by the distance between the different raised areas, the number of different raised areas, and the area covered by the distal raised area on the distal side of the first body.

[0334] In addition, the energy required for mechanical excitation to liquefy the thermoplastic material can be reduced by arranging a plurality of distinct protrusions on the distal side of the first body, rather than a large, continuous protrusion. This reduces the energy required to liquefy the thermoplastic material and can thereby prevent the excited natural oscillations from becoming destructive.

[0335] · Device body with uneven physical properties.

[0336] This feature includes a device body having a hole (opening). Specifically, the hole can make the shape of the device body conform to the shape of the coupling-out face of the soldering electrode.

[0337] Natural oscillations, destructive deformations (here meaning deformations leading to material failure due to stress) and combinations thereof of the type described above can be formed in a third body that is fixed to the second body via the first body.

[0338] This is particularly the case when the third object is rigid, such as a metal sheet, and / or if the third object does not comprise an opening for the protrusion(s) of the first object or is not suitable for the protrusion(s). The opening may be unsuitable for the protrusion by having a smaller diameter than the protrusion or by not being a through hole, wherein the length of the protrusion is greater than the depth of the opening.

[0339] Uncontrolled material failure of the third object during the method can adversely affect the reliability of the article comprising the third object bonded to the second object via the first object, as such material failure can be a source of failure in the article. For example, cracks can amplify and propagate during use of the article.

[0340] Destructive natural oscillations and destructive deformations can be avoided by properly designing the first object. Specifically, the first object may include at least one of the following features:

[0341] The first object comprises a protruding structure capable of damping the natural oscillations of the third object and / or capable of preventing the third object from deforming at a critical position.

[0342] The protrusions may have the same length, which means that they may extend equidistantly in the distal direction.

[0343] In an embodiment, the first object may include a first row of protrusions and a second row of protrusions. The rows may follow a straight line or a curve. The rows may extend parallel to each other.

[0344] • The distal surface of the first object may comprise regions extending diverging from each other in the distal direction.

[0345] For example, the area between the first and second rows may be offset from another area on the distal side of the first object.

[0346] The first object may comprise a damping element arranged on a distal side of the first object. In particular, the damping element may be designed to come into contact with the third object during the method.

[0347] The rows of protrusions can form a damping element. However, a single protrusion is sufficient to damp the natural oscillations. The exact design of the damping element depends on various parameters, such as the size of the first object, the size and material of the third object, etc.

[0348] Herein, the expression "a thermoplastic material capable of being rendered flowable, for example, by mechanical vibration," or simply "liquefiable thermoplastic material," "liquefiable material," or "thermoplastic," is used to describe a material comprising at least one thermoplastic component that becomes liquid (flowable) upon heating, particularly when heated by friction, i.e., when arranged on one of a pair of surfaces (contact surfaces) that are in contact and vibrating relative to one another, wherein the frequency of the vibrations has the properties discussed above. In certain circumstances, such as when the first object itself must bear a significant load, it may be 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, as the vibration-conducting properties of the thermoplastic material of the first object are not effective during processing. In particular, because the profile body has a relatively small extension in the proximal and distal directions, the method is also suitable for securing a relatively thin first or second object to a second or first object (including the possibility that both objects are thin). The method of the present invention also works with thermoplastic materials that are poor vibration conductors, such as those with a low elastic modulus and / or elastomeric properties. In this case in particular, the shape of the profile body ensures that the contact with the counterpart is essentially linear. This has a high energy concentration effect and enables localized liquefaction even with the strong damping properties of the thermoplastic material.

[0349] Thermoplastic materials are well known in the automotive and aerospace industries. For the purposes of the method according to the invention, thermoplastic materials known for use in these industries can in particular be used.

[0350] 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 implemented). It preferably comprises a polymeric phase (particularly based on C, P, S or Si chains) which is converted from a solid state to a liquid state or flowable above a critical temperature range (e.g., by melting) and which is converted back into a solid material when cooled again to 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 that of the liquid phase. Thermoplastic materials will generally comprise polymer components that are not covalently crosslinked or crosslinked, and the crosslinking bonds are reversibly opened when heated to or above the melting temperature range. The polymeric material may also comprise fillers, such as fibers or particulate materials, which do not have thermoplasticity or have thermoplasticity comprising a melting temperature range that is significantly higher than the melting temperature range of the base polymer.

[0351] In this context, a "non-liquefiable" material is generally a material that cannot be liquefied at the temperatures reached during the process, and therefore in particular at the temperature at which the thermoplastic material of the connector is liquefied. This does not exclude the possibility that the non-liquefiable material can be liquefied at a temperature not reached during the process, but generally well above the liquefaction temperature of the thermoplastic material or the liquefaction temperature of the thermoplastic material during the process (e.g. at least 80°C). The liquefaction temperature is the melting temperature of a crystalline polymer. For amorphous thermoplastics, the liquefaction temperature (also referred to as the "melting temperature in this context") is the temperature above the glass transition temperature at which it becomes sufficiently fluid, sometimes referred to as the "flow temperature" (sometimes defined as the lowest temperature at which extrusion is possible), e.g. the temperature at which the viscosity of the thermoplastic material drops to below 104 Pa*s (in embodiments, in particular for polymers that are substantially free of fiber reinforcement, below 103 Pa*s).

[0352] For example, the non-liquefiable material can 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 which is significantly higher than the melting temperature / glass transition temperature of the liquefiable part, for example the melting temperature and / or glass transition temperature is at least higher than 50°C or 80°C or 100°C.

[0353] Specific examples of thermoplastic materials are: polyetherketone (PEEK), polyesters such as polybutylene terephthalate (PBT) or polyethylene terephthalate (PET), polyetherimide, polyamides such as polyamide 12, polyamide 11, polyamide 6 or polyamide 66, polymethyl methacrylate (PMMA), polyoxymethylene or polycarbonate polyurethane, polycarbonate or polyester carbonate, or acrylonitrile butadiene styrene (ABS), acrylate-styrene-acrylonitrile (ASA), styrene-acrylonitrile, polyvinyl chloride (PVC), polyethylene, polypropylene and polystyrene, or copolymers or mixtures of these.

[0354] In embodiments where both the first and second objects comprise thermoplastic materials and a weld is not desired, the material pair is selected such that the melting temperature of the second object material is substantially higher than the melting temperature of the first object material, for example, at least 50° higher. A suitable material pair is, for example, polycarbonate or PBT for the first object and PEEK for the second object.

[0355] In addition to the thermoplastic polymer, the thermoplastic material may also include suitable fillers, for example reinforcing fibers, such as glass fibers and / or carbon fibers. The fibers may be short fibers. Long fibers or continuous fibers may be used, in particular, for the portions of the first and / or second objects that are not liquefied during the process.

[0356] The fiber material, if any, may be any material known for fiber reinforcement, in particular carbon, glass, Kevlar, ceramics such as mullite, silicon carbide or silicon nitride, high strength polyethylene (Dyneema), and the like.

[0357] Other fillers that do not have a fibrous shape are also possible, such as powder particles.

[0358] Mechanical vibrations or oscillations suitable for use in embodiments of the method according to the present invention preferably have a frequency between 2 and 200 kHz (even more preferably between 10 and 100 kHz, or between 20 and 40 kHz) and a vibration energy of 0.2 to 20 W / mm² of active surface. The vibrating tool (e.g., an ultrasonic welding head) is designed, for example, so that its contact surface oscillates primarily in the direction of the tool axis (longitudinal vibration) and with an amplitude of between 1 and 100 microns, preferably about 30 to 60 microns. Such preferred vibrations are generated, for example, by ultrasonic devices known, for example, from ultrasonic welding.

[0359] In this document, the terms "proximal" and "distal" are used to indicate direction and position, i.e., "proximal" refers to the side of the connector where the operator or machine applies mechanical vibration, while "distal" is the opposite side. The widening of the connector on the proximal side is referred to as the "head," while the widening on the distal side is the "foot." BRIEF DESCRIPTION OF THE DRAWINGS

[0360] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. The drawings are schematic and not to scale. In the drawings, identical reference numerals denote identical or similar elements. The drawings are provided to illustrate the present invention and its embodiments and are not intended to limit the scope of the invention. Terms referring to directions, such as "near" and "far," are used in the same manner throughout the embodiments and drawings.

[0361] The accompanying drawings show:

[0362] Figure 1: an assembly of the first and second objects before joining the first object to the second object;

[0363] Figure 2 : a first object and a second object in the process of combining;

[0364] Figure 3a : Cross-sectional view of an example bonding site;

[0365] Figures 3b-3d : Cross-sectional views of another example bonding location at three stages of the bonding process;

[0366] Figure 4 and 5 : an example embodiment of a first object;

[0367] Figure 6 and 7 : An example embodiment of a first object comprising a connection device element;

[0368] Figure 8 and 9 : An example embodiment of a first object forming an element of a connecting device;

[0369] Figure 10-13 : An example embodiment of a method of bonding a first object to a second object, comprising increasing density along an axis of driving the first object into the second object;

[0370] Figure 14 and 15 : A cross-sectional view of attaching a third object to a second object by employing an embodiment of the first object and method;

[0371] Figure 16 : another embodiment of the first object;

[0372] Figures 17a-17e : Other embodiments of the first object include structure for promoting localized compression of the second object;

[0373] Figure 18 : a cross-sectional view of an object attached to a second object by employing an embodiment of a first object, another object, and a method;

[0374] Figure 19a and 19b : Cross-sectional views before and after attaching a third object to a second object by employing the first object;

[0375] Figure 20a and 20b : a cross-sectional view before and after a first object is attached to a second object, the second object comprising a rigid proximal top layer;

[0376] Figure 21a and21b : Cross-sectional views of an example embodiment of a first object including protrusions of different lengths before and after being attached to a second object;

[0377] Figure 22 and 23 : Cross-sectional views of several example embodiments of a first object including protrusions of different lengths after the first object is attached to a second object;

[0378] Figure 24 : Example embodiments of methods including a support for a second object;

[0379] Figure 25a and 25b : Example embodiment of a second object designed to protect an edge of a first object;

[0380] Figures 26a-26e : Cross-sectional views of attaching a third object to a second object by employing a first object at different stages of a bonding process;

[0381] Figures 27a-27d : Cross-sectional views of attaching another third object to a second object by employing the first object at different stages of the bonding process;

[0382] Figure 28 : An example embodiment of a first object comprising a plurality of protrusions, wherein the plurality of protrusions are confined in volume;

[0383] Figure 29a and 29b : Cross-sectional views of a first object bonded to a second object of another type, before and after bonding;

[0384] Figure 30a and 30b : cross-sectional views of a second object of yet another type and a first object bonded to a second object of this type before and after bonding;

[0385] Figure 31 : A cross-sectional view of yet another third object bonded to the second object by using the first object;

[0386] Figure 32a and 32b : a cross-sectional view of a first object bonded to a second object by a method including the step of providing an adhesive;

[0387] Figure 33a and 33b : an example embodiment of a first object being a connector;

[0388] Figures 34-39 : showing exemplary embodiments of the protruding area of ​​the first object and the device respectively;

[0389] Figures 40-43 : Various exemplary embodiments of the first object and the device are shown respectively;

[0390] Figures 44-46 : Three example embodiments of a first object configured to prevent destructive natural oscillations;

[0391] Figures 47-49 : An example embodiment of a first object comprising a fixing element and a connecting element;

[0392] Figure 50 and 51 : Alternative fixing method of the third object to the second object through the first object;

[0393] Figure 52 and 53 : A cross-sectional view of attaching a third object to a second object by employing the first object;

[0394] Figure 54a and 54b : A cross-sectional view of attaching a metal sheet without pre-drilled holes to a second object by using a first object;

[0395] Figure 55 :Can be used according to Figure 54a and 54b Example embodiment of the first object in the method;

[0396] Figure 56 : a basic arrangement of first and second objects between which the first object is joined to the second object by applying a welding electrode to the second object;

[0397] Figure 57a and 57b :Basis before and after combination Figure 56 Example applications of the method;

[0398] Figure 58 : An embodiment of the method wherein the electrode is applied to the second object and a force is applied to the first object for driving the protrusion to penetrate into the low density area; and

[0399] Figure 59 : Two representative stress-strain curves for panels formed from uncross-linked material. DETAILED DESCRIPTION

[0400] The method according to the present invention comprises providing a first object 1, providing a second object 2 and arranging the first object 1 relative to the second object 2 so that the first object 1 is in physical contact with the proximal side 4 of the second object 2 and forming an assembly of the first and second objects. An exemplary embodiment of this assembly is Figure 1 Shown in.

[0401] In the illustrated embodiment, both the first object 1 and the second object 2 extend over an extended area. The first object 1 may have the same dimensions as the second object. However, it is also possible that the first object 1 only partially and / or partially covers the proximal side 4 of the second object 2.

[0402] The second object 2 and / or the first object 1 may be non-planar. In particular, in configurations where the second object 2 extends over a larger area than the first object 1, the second object 2 may be non-planar, for example, by virtue of having a shape that conforms to the surface to be covered by the second object 2, whereas the first object 1 is planar. This planar first object 1 may then be bonded to the planar proximal side region of the second object 2, or the first object 1 may be deformed during the bonding process so that its shape conforms to the shape of the second object 2.

[0403] In the embodiment shown, the first body 1 extends between a proximal end 5 and a distal end 6 and is composed of a thermoplastic material.

[0404] exist Figure 1 In the embodiment shown, the first body 1 comprises a ridge-like, conical protrusion 9 at its distal end 6 .

[0405] The ridge extends from a main body 7 of the first object 1 (also referred to as first object body or device body), said main body 7 forming the proximal end 5 of the first object 1 .

[0406] In order to connect another object to the first object 1 , a main body 7 and / or a connecting device element 15 attached or attachable to the main body 7 may be provided.

[0407] The second object 2 has an increasing density in the normal direction of the proximal side 4 and further comprises structures 10 , such as pores, into which the liquefied material can penetrate.

[0408] This increased density may, for example, be due to a change in composition of the second object 2 along said direction and / or to a reduction in said structure.

[0409] Due to this change, the second object 2 includes a region 22 having a density lower than that of a region 23 , which is arranged on the far side of the low-density region 22 .

[0410] The region 22 having a lower density than the region 23 arranged distally is also referred to as a proximal region 22 , whereas the distal region 23 arranged relative to the proximal region 22 is also referred to as another region 23 .

[0411] exist Figure 1 In the embodiment shown, the second object 2 comprises a plurality of fibers ( Figure 1The fiber portion not embedded in the plastic forms a soft surface layer. In the region where the fibers are embedded in the plastic, the density of the soft surface layer is less than that of the second object 2.

[0412] Thus, the composition and density of the structure 10 varies along the normal to the proximal side 4. The soft surface layer corresponds to the low-density region 22 and the region with the fibers embedded in the plastic corresponds to the high-density region 23.

[0413] The enlarged portion immediately adjacent to the second object 2 shows Figure 1 The second object 2 may comprise other density regions, such as a second region of low density forming the near side of the second object 2 or a transition region extending between regions of low density and high density.

[0414] As indicated above, the high-density region may include a plurality of structures, voids, openings, etc. In addition, it is compressible, for example, capable of being compressed to a critical density and / or compressed in such a manner that the high-density region provides a critical compressive strength. The term "critical" relates to the density and / or compressive strength required for the thermoplastic material to liquefy in the present method.

[0415] Figure 2 shows that a mechanical pressing force (by Figure 2 ) and mechanical oscillation (indicated by the double-headed arrow) of the assembly of the first and second objects, the axis 8 being substantially perpendicular to the proximal side 4 of the second object 2.

[0416] The mechanical pressing force and the mechanical oscillation are applied by a welding electrode 20 , which comprises an output surface 21 in contact with the proximal side 4 of the first object 1 .

[0417] In the exemplary embodiment shown, the coupling-out surface 21 is provided for subjecting a portion of the first object 1 only to mechanical oscillations and / or mechanical pressing forces, thereby forming a precisely defined, localized joining point 13 during the joining process. Figure 2 , four bonding sites 13 are shown. However, the number of bonding sites 13 depends, for example, on the shape and size of the first object 1, the shape and material of the second object 2, and the bonding requirements (for example, its strength).

[0418] An advantage of the illustrated bonding method is that the number and arrangement of the bonding locations 13 can be easily adjusted even during bonding by applying the welding electrode 20 to positions on the near side of the first object 1 .

[0419] In the illustrated embodiment, the mechanical pressing force is also oriented along the axis 8 of the mechanical oscillation. However, the mechanical pressing force is initiated before the mechanical oscillation. This has the effect that the protrusions 9 penetrate at least the low-density region 22 before liquefying. This allows the connection between the first and second objects 2 to no longer be limited to the proximal side 4 but instead rely on the structure 10 within the second object 2. In other words, a deep anchoring is achieved, compared to a surface anchoring, for example, achieved with an adhesive.

[0420] The density distribution of the second object 2 may be such that there is no need to start applying mechanical pressing force before mechanical oscillation. In this case, once the density of the second object has reached a level that allows the compressed thermoplastic material 3 to begin liquefying, the thermoplastic material 3 begins to liquefy.

[0421] The second object Figure 2 It is shown in a schematic manner only. Figure 2 The second object shown in may specifically correspond to Figure 2 , 3 or the second object shown in 10-13.

[0422] Figure 3a Shown along Figure 2 The cross-sectional view of the AA axis shown in FIG. Figure 1 The second object 2 is shown in FIG.

[0423] The combined effect of the mechanical pressing force and the mechanical oscillation has caused part of the thermoplastic material 3 of the protrusion 9 to come into contact with the high-density area 23, to liquefy and penetrate into the structure of the second body 2. This results in a positive connection between the first and second bodies after the liquefied thermoplastic material 3 has resolidified, in particular a positive connection about the axis of oscillation 8, i.e. a positive connection that prevents relative movement of the first and second bodies in the normal direction of the proximal side 4.

[0424] Figures 3b-3d A cross-sectional view showing a bond established between a first object 1 and a second object 2 having a uniform density distribution in a direction perpendicular to a near side surface 4 of the second object 2 is shown.

[0425] Figure 3b The situation before the protrusion 9 of the first object 1 is pushed into the second object 2 is shown.

[0426] Figure 3c The situation is shown during the step of pushing the protrusion 9 and the body 7 into the second object 2 if the density of the second object is such that the body can be pushed into the second object without destroying the first or second object and / or their properties.

[0427] The penetration of the protrusion 9 (and optionally the body 7) compresses the second body 2 at least partially around the distal end of the protrusion 9. This creates the density distribution required to liquefy the thermoplastic material 3 of the protrusion 9 by applying a mechanical pressing force and mechanical stimulation.

[0428] Figure 3d The situation is shown after the step of stopping the mechanical actuation. The liquefied thermoplastic material 3 has penetrated the structure 10 of the second object 2.

[0429] The liquefied thermoplastic material 3 can penetrate into the uncompressed or only slightly compressed areas of the second body 2. In this case, the bonding ratio of the first body to the second body ensures that the deeply anchored protrusions 91 penetrate deeper into the second body 2.

[0430] Figure 4 An embodiment of a first object 1 is shown which is similar to the embodiment as provided in the method of joining a first object 1 to a second object 2. Figure 1 and 2 The first object shown in .

[0431] One can imagine that the protrusion 9 is different from the Figure 4 The protrusions are shown in FIG. Figure 5 An exemplary embodiment of the first object 1 is shown, wherein the protrusions 9 are given as a plurality of points.

[0432] The protrusions 9 extend from the distal side 28 of the main body 7 of the first object 1. They are arranged in a protrusion area 90 located distally of the distal side 28 of the main body 7 of the first object 1.

[0433] The first object 1 further comprises a proximal side 29 of the main body 7 of the first object 1 (at Figure 4 and 5 Hidden in Figure 6 、 8 and 9 ), said proximal side forming the proximal end 5 of the first object 1 during and after the method.

[0434] Figure 1 The method shown in FIG. 3 can be used to bond a connecting device element 15 to a second object 2 . This can be done by a first object 1 comprising such a connecting device element 15 .

[0435] The first object 1 may comprise a first object 1 of a connecting mechanism or a plurality of connecting device elements 15. For example, the plurality of connecting device elements 15 may be arranged according to Figure 4 or 5 is arranged on the near side of the first object 1 .

[0436] Figure 6 An exemplary embodiment of a first object 1 is shown, comprising a connecting device element 15 . Figure 7A cross-section of the first object 1 with an applied welding electrode 20 is shown.

[0437] In the embodiment shown, the connecting device element 15 is a rod with an internal thread.

[0438] In the exemplary embodiment shown, the first object 1 comprises a coupling surface 11 which is arranged around a protruding connecting device element 15 on the proximal side of the first object 1 .

[0439] The distal end of the welding electrode 20 , ie the end of the welding electrode 20 comprising the outcoupling face 21 , is conformed to the first object 1 by comprising an opening into which the rod can be inserted so that it is not loaded during the joining process.

[0440] exist Figure 6 In the embodiment of FIG. 1 , the protrusions 9 are again ridge-shaped. However, the first object 1 may comprise protrusions of different shapes, such as points.

[0441] The first body 1 may for example comprise one, two, three or four tips. In embodiments where the first body 1 is small and / or defines a binding site 13 by itself, a small number of protrusions 9 may be sufficient, e.g. Figure 7 shown.

[0442] Once again, the protrusion 9 is arranged distally of the distal side 28 of the main body 7 of the first object 1 in a protrusion region 90 .

[0443] The area of ​​the outcoupling face 21 can be equal to or greater than the area of ​​the proximal side face, in particular if the first body 1 itself defines a bonding location 13 .

[0444] Figure 8 and 9 Shown are schematic and cross-sectional views of a first object 1 which is in fact a connector 16. In other words, the first object 1 comprises elements of a latching mechanism mounted on a thermoplastic device, which can be joined to a second object 2 by any embodiment of the joining method.

[0445] Figure 9 A cross-section of the first object 1 is shown. In the exemplary embodiment shown, the protrusions 9 are separated from one another by gaps 27 extending to a proximal side 29 of the main body 7 of the first object 1 .

[0446] In the embodiment shown, the projections 9 are arranged and designed such that a flat region of the proximal side 29 extends between them. Said flat region can be used as a stop surface.

[0447] Figure 10-12 An embodiment of the method is shown, wherein a first object 1 (e.g. according to Figure 4-9 The first object 1) penetrates the high-density area before the thermoplastic material 3 starts to liquefy.

[0448] exist Figure 10-13 The second object comprises a proximal side layer 17, a distal side layer 18 and a core layer 19, wherein the density of the distal side layer and the proximal side layer is less than the density of the core layer 19. However, the method described below is also applicable to a material having, for example, Figure 1 The difference between the second object 2 and the density distribution of the second object 2 is generated.

[0449] For example, the proximal and distal side layers include or consist essentially of a damping material, whereas the core layer 19 consists of a damping material embedded in another material or consists of a material other than the damping material that is denser than the damping material and has a higher mechanical stability than the damping material.

[0450] Figure 10 It shows that the first mechanical pressing force (by Figure 10 The small arrow at the top indicates the situation after the step of ), this first mechanical pressing force is smaller than the second mechanical pressing force applied to the first object 1 in the subsequent steps of the method. No mechanical oscillation is currently applied.

[0451] The protrusions 9 of the first object 1 have passed through the near-side layer 17 , but have not yet penetrated the core layer 19 .

[0452] Figure 11 shows that when the second mechanical pressing force (by Figure 11 The large arrow at the top indicates the situation in step ). No mechanical oscillation is currently applied.

[0453] The protrusion 9 has penetrated the core 19 and is able to penetrate further into the core 19. This means that movement of the first object 1 relative to the second object 2 along the penetration axis is not hindered by any element of the first or second object.

[0454] Specifically, the optionally present stop surface has not yet generated a reaction force to the applied pressure to prevent the first object 1 from further penetrating the second object 2 .

[0455] If formed in Figure 11 At the stage shown in , a mechanical oscillation is then applied (indicated by a double-headed arrow).

[0456] Figure 12 The thermoplastic material 3 has penetrated into the structure 10 of the core 19 and has formed a positive connection between the first and second bodies, in particular in a direction orthogonal to the penetration direction of the first body 1 .

[0457] However, the protrusion 9 does not completely disappear during the process, for example by becoming "blurred". Instead, the protrusion 91 remains at the location where the protrusion 9 was before the mechanical oscillation was applied. This, for example, creates a depth-dependent anchoring.

[0458] The stop surface 12 generates a reaction force against the second mechanical pressing force in the final stage of the bonding process, wherein the reaction force limits the movement of the first object 1 toward the distal layer 18. Thus, the maximum penetration depth of the first object 1 into the second object 2 is limited by the stop surface 12 and the length of the protrusion 9 in the normal direction of the stop surface.

[0459] In the exemplary embodiment shown, the stop surface 12 is a surface of the first body 1 which extends normal to the penetration direction of the first body 1 , ie normal to the axis 8 of the mechanical oscillation.

[0460] In the embodiment shown, the length of the protrusions 9 is such that the distal side 14 of the second object 2 is neither in contact with nor affected by the thermoplastic material 3. Furthermore, the density of the core layer 19 (high-density region 23) at any bonding location 13 is such that liquefaction of the thermoplastic material is possible at least without involving other materials or surfaces.

[0461] The core layer 19 shown comprises a material or is composed of a composite material that provides mechanical stability for the second body 2. The second body 2 can be flexible, in particular elastically flexible. However, the material or composite material of the core layer 19 allows the thermoplastic material 3 to liquefy at the interface between the thermoplastic material 3 and the material or composite material of the core layer 19 under the influence of mechanical oscillations and mechanical compressive forces. In particular, the material or composite material provides the rigidity required for such liquefaction.

[0462] In particular, the physical properties of the distal layer 18 are neither necessary nor relevant during the liquefaction of the thermoplastic material 3 .

[0463] Figure 13 Shown by Figure 10-12 The method establishes a bond without applying a second mechanical pressing force or by applying a second mechanical pressing force and mechanical oscillation simultaneously.

[0464] The penetration depth of the thermoplastic material 3 is limited to the proximal side layers 17 of the core layer 19 and the adjacent areas of the core layer 19 .

[0465] Figure 14 and 15 A cross-section through an assembly of first, second and third objects is shown, wherein the third object 30 is attached to the second object 2 via the first object 1 and wherein the first object 1 is bonded to the second object 2 by an embodiment of the method.

[0466] The third object 30 includes a third object proximal side 31 and a third object distal side 32. The third object 30 is arranged opposite to the second object 2 so that its distal side 32 is in physical contact with the proximal side 4 of the second object 2.

[0467] exist Figure 14 In the illustrated embodiment, the third object 30 may have any density distribution from a third object proximal side 31 to a third object distal side 32 that can be penetrated by the protrusion(s) 9 of the first object 1 .

[0468] In particular, the third object 30 may have any density distribution described with reference to the second object 2 .

[0469] It is thereby possible to bond the first object 1 to the third object 30 by employing corresponding method steps and corresponding structures 35 of the third object 30 .

[0470] exist Figure 15 In the embodiment shown, the third object 30 also comprises a low-density region 36 on its proximal side 31. In addition, the first object 1 comprises protrusions 33 of the first type and protrusions 34 of the second type.

[0471] The length and diameter of the first type protrusions 33 are such that the distal ends of the first type protrusions 33 at least partially penetrate into the low-density region 22 of the second object 2 and penetrate into the structure 10 of the second object 2 during bonding.

[0472] The length and diameter of the second type protrusions 34 are such that the distal ends of the second type protrusions 34 at least partially penetrate into the low-density region 36 of the third object 30 and penetrate into the structure 35 of the third object 30 during bonding.

[0473] Specifically, the diameter of the first type protrusion 33 is greater than the diameter of the second type protrusion 34 .

[0474] Figure 16 and 17a -17e shows an example embodiment of a first object 1 .

[0475] Figure 16 The embodiment shown in FIG corresponds to forming the first, second and third objects as Figure 15 The embodiment provided in the method of assembly is shown.

[0476] Figures 21-23 show other configurations in which the Figure 16 The first object 1.

[0477] The cross-sections of the first type protrusions 33 and the second type protrusions 34 are not necessarily the same and / or circular.

[0478] However, in Figure 16 In many embodiments of the first object 1 shown in FIG, the cross-sectional area of ​​the first type of protrusions 33 is larger than the cross-sectional area of ​​the second type of protrusions 34 .

[0479] Figure 16 The thickness 26 of the protrusions 9 and their extension 25 in the distal direction are shown. Said extension is equal to the distance of the most distal point of the protrusion from the distal face 28 of the main body 7 of the first object 1 . Figure 17a -e shows the embodiment of the first object 1 not only by the protrusion of the second object 2 replacing the material (e.g. Figures 3b-3d ) but also locally increases the density of the second object 2 by including structures 24 specifically designed and arranged to promote local compression of the second object 2 (especially the low-density areas 22).

[0480] The structure 24 shown is also designed and arranged to pull down the fiber material of the second object 2 and / or further bind this material and / or better embed the protrusions 9 comprising this structure 24 into the material of the second object 2, for example to distribute any load over a larger area.

[0481] exist Figure 17a 、 17b The embodiment of the first object 1 shown in FIG. 17 and FIG. 17 e comprises so-called barbs 24 , ie structures having a certain shape and arranged at the protrusions 9 so as to increase the density of the second object 2 towards which the protrusions 9 are directed at the penetration depth of the protrusions 9 .

[0482] The barb Figure 17a It is shown arranged at the distal end of the protrusion 9. This results in a local compression of the second body 2, which helps to liquefy the thermoplastic material 3 arranged around the distal end of the protrusion.

[0483] Alternatively or additionally, the barbs 24 may be arranged on lateral sides of the projection 9 . Figure 17b The pull-down barb is shown, which is small compared to the size of the protrusion 9, Figure 17e The grabbing barbs are shown, having dimensions that contribute to the overall shape of the protrusion.

[0484] The barbs 24 do not necessarily need to be evenly distributed on the lateral sides. Rather, the barbs 24 may be arranged so that the liquefaction of the thermoplastic material 3 begins at certain locations on the protrusion 9 and / or the penetration of the liquefied thermoplastic material into the second object 2 is limited along a specific direction.

[0485] exist Figure 17c and 17d In the embodiment, the structure 24 designed and arranged to promote local compression of the second object 2 is given by the shape of the distal end of the protrusion, in particular by having a plurality of tips which eg induce gripping of fibers.

[0486] In particular, the barbs are suitable for a fibrous second body 2 , in which they can collect the fibers during penetration and thus increase the density of the fibers around the projection 9 .

[0487] The barbs may be made of thermoplastic material 3 or a harder material.

[0488] The barbs made of thermoplastic material 3 may further increase the embedding of the protrusion 9 and the projection 91 , respectively.

[0489] Barbs may also be arranged at the first type protrusions 33 and / or the second type protrusions 34 .

[0490] exist Figure 14-1 The first object 1 shown in 7 may further comprise at least one connecting device element 15 .

[0491] Figure 14-1 The first object 1 shown in 7 may be a connector as described above.

[0492] Figure 18 A cross-sectional view shows the result of an embodiment of the method, wherein an object 100 different from the first and second objects is attached to the second object by connecting another object 40 to the first object 1 .

[0493] In the embodiment shown, the first object 1 is a reinforcement.

[0494] The further object 40 is a fastener (such as a nail) having a pointed distal end 41. The further object 40 further comprises an attachment site 42 arranged to penetrate the object 100 to be attached to the second object 2 and into the body 7 of the first object 1.

[0495] The first object 1 is bonded to the second object 2 by any of the above-described embodiments. More specifically, the first object 1 is bonded to the second object 2 by a method such that the protrusion 91 is located within the second object after the mechanical actuation is stopped and the thermoplastic material is solidified.

[0496] Figure 19a A cross-sectional view of a third object 30 is shown before it is attached to the second object 2 by bonding the first object 1 to the second object 2. In the embodiment shown, the third object comprises a thermoplastic material at least in the areas where the third object is pierced by the protrusions 9. For example, the third object 30 shown in FIG19 may be a thermoplastic foil.

[0497] Figure 19bA cross-sectional view of a third object 30 attached to a second object 2 is shown. During the method of joining the first object 1 to the second object 2, a weld 203 is formed between the first object 1 and the third object 30. This is formed by the third object 30 comprising thermoplastic material in the area pierced by the protrusion.

[0498] The thermoplastic material of the third object 30 and the thermoplastic material 3 of the first object 1 arranged at the proximal end of the protrusion 9 and / or the thermoplastic material of the distal side 28 of the adjacent main body 7 liquefy under the application of mechanical pressing force and mechanical stimulation. However, it is conceivable that the liquefaction condition of the thermoplastic material(s) can only be achieved after the second object 2 is compressed by pushing the main body 7 into the second object 2.

[0499] Figure 19b A mechanism is shown that can further increase the quality of the bond between the first and second objects. Although shown in conjunction with establishing a weld 203 between the first and third objects, the mechanism can be used in any embodiment of the present invention, regardless of the presence of the third object 30.

[0500] An embodiment comprising the described mechanism comprises a second body 2 comprising a thermoplastic material in the region where the bond between the first and second bodies is established. This thermoplastic material is capable of liquefying or at least softening under the influence of the mechanical pressing forces and mechanical stimuli applied during the method of bonding the first body 1 to the second body 2. In a variant embodiment, the thermoplastic material is capable of liquefying / softening only after it has been compressed by pushing the protrusions 9 and / or the body 7 into the second body 2.

[0501] Due to said liquefaction or softening, said second object 2 comprises a region 202 having altered structural properties after the step of resolidifying (in this case all) the thermoplastic material. A higher density and / or more cross-linked material of the second object 2 is an example of said altered structural properties.

[0502] Figure 20a and 20b A first object 1 is shown bonded to a second object 2 , the second object comprising a proximal top layer 200 that is not part of the low-density region 22 .

[0503] For example, the proximal top layer 200 is the rigid top layer of a hollow core board (HCB).

[0504] Figure 20a The situation is shown after positioning the first object 1 relative to the second object 2. The protrusions 9 of the second object 2 are designed to penetrate the proximal top layer 200 without significant deformation. In addition, they may also include a distal tip or edge.

[0505] Figure 20bThe situation after bonding the first object 1 to the second object 2 is shown. This illustrates a situation in which the unaffected layer disposed distally to the proximal top layer 200 is not sufficiently dense to allow the thermoplastic material 3 to liquefy within a practical timeframe for professional use. Again, the creation of the compression zone 201 enables bonding of the first object 1 to the second object 2.

[0506] Figures 21-23 show an embodiment of a method comprising a protrusion with adjusted length, wherein the length is adjusted, for example, depending on: the thickness of the second object 2, the layer structure of the second object 2, the mechanical properties of the body 7, the shape of the body and / or the preparation steps after the first object 1 is bonded to the second object 2.

[0507] Figure 21a and 21b It is shown that the first object 1 includes a first type of protrusions 33 and a second type of protrusions 34 , wherein the first type of protrusions 33 are longer than the second type of protrusions 34 .

[0508] The length of the first type protrusion(s) 33 is greater than the thickness of the second object 2 in the direction in which the first type protrusion 33 penetrates and passes through the second object 2 .

[0509] In this case, the method comprises the further step of providing an anvil 60 comprising a deforming recess 61. The deforming recess 61 is positioned so that the distal end of the protrusion 9 engages with the deforming recess 61 after passing through the second object 2. The distal end of the protrusion 9 can then be deformed within the distal head 62 by applying a mechanical compressive force and mechanical stimulation to the first object 1 or to the anvil 60.

[0510] The second type protrusion(s) 34 have a length allowing joining the first object 1 to the second object 2 , for example by a method comprising creating a compression zone 201 , within the second object 2 and according to any embodiment of the invention.

[0511] The protrusion arrangement in which the first type protrusions 33 are arranged close to the ends (which means the lateral edges of the body 7 and the second type protrusions 34 are arranged radially inside the first type protrusions 33) is structurally advantageous, wherein for example:

[0512] The body 7 of the first object 1 is not sufficiently rigid to remain in place over a larger area and / or for a longer period of time;

[0513] After initially but permanently bonding the second object 2 to the first type of protrusions, the second object 2 is deformed.

[0514] Figure 22 Another arrangement of protrusions 9 of different lengths is shown after joining the first object 1 to the second object 2. In the embodiment shown, the length of the existing protruding portion 91 is related to the length of the protrusion.

[0515] Figure 22 The embodiment shown is an example of a first body 1 comprising a protrusion which is optimized with respect to material costs and the forces acting on the bond between the first and second bodies in a particular application. The embodiment shown is particularly suitable for applications in which the bonded first and second bodies are bent, which means the application of bending forces.

[0516] Figure 23 An embodiment is shown in which the second object 2 comprises a layer structure. The first object 1 again comprises a first type of protrusion 33 and a second type of protrusion 34. The length of the protrusion is adjusted so that a bond is formed in a first low-density area 204 or a second low-density area 205, which is arranged further to the side than the first low-density area 204.

[0517] Figure 23 A simple arrangement of layers forming the second object 2 is shown. However, the length and arrangement of the first type of protrusions 33, the second type of protrusions 34, and, if appropriate, other types of protrusions, can be adjusted to accommodate more complex arrangements of layers. Specifically, the layers need not extend parallel to one another, have a uniform thickness, and / or extend over the entire extent of the second object 2. For example, a layer (e.g., a low-density layer) can be arranged locally, meaning that it only needs to be present at the location where the first object 1 is joined to the second object 2.

[0518] Additionally, the second object 2 need not include a rigid proximal top layer 200 or include a rigid layer 206 between low-density regions.

[0519] In principle, there is no need for any rigid layer 206 or any area with a density that imparts load-bearing capacity to the second object 2. In this case, the method may comprise at least the step of providing a support 63 during the method of bonding the first object 1 to the second object 2. This configuration is Figure 24 Shown in.

[0520] Figure 24 The situation is shown after the thermoplastic material 3 has started to liquefy. If the second object 2 does not comprise high-density areas at all, then the compression zone 201 needs to be established before the thermoplastic material 3 starts to liquefy.

[0521] The anvil 60 is an example of this support 63. However, the support 63 may also be given by an item to which the second object 2 is attached.

[0522] Figure 25aThe present invention illustrates a method application in which a mechanical compressive force and a mechanical excitation are locally applied to a first object 1 and the steps of applying the mechanical compressive force and the mechanical excitation are repeated multiple times at different locations on the first and second objects. Consequently, there are multiple bonding sites 13 that are not arranged on a single plane and cannot be processed in a single step of applying the mechanical compressive force and the mechanical excitation.

[0523] In the embodiment shown, the first object 1 is a protector of an edge or corner of the second object 2 .

[0524] Figure 25b Shown according to Figure 25a sectional view of a first object 1 attached to a second object 2. The first bonding site 13 is arranged on a first side of the second object 2, and the second bonding site 13 is arranged on a second side of the second object 2, the first side being non-parallel to the second side.

[0525] In the embodiment shown, the first object 1 is pushed into the second object 2 in such a way that the distal side 28 of the body 7 is at the same height as the corresponding surface of the second object 2. This arrangement of the first and second objects is not exclusive to Figure 25a and 25b Rather, the application shown in can be implemented in any embodiment of the method comprising a second object 2 having a proximal side 4 allowing it to be pushed into a body 7 of a first object.

[0526] In many embodiments, the corresponding surface of the second object 2 is the proximal side 4 .

[0527] Pressing the body 7 into the second object 2 such that the distal surface(s) 28 of the body 7 are at the same height as the corresponding surface(s) of the second object 2 has the effect of compressing the second object 2 overall at least in the region where the body 7 is pushed into the second object 2. The resulting compressed region 201, particularly in combination with the localized compression caused by the protrusions 9, may be necessary for effectively liquefying the thermoplastic material 3, as described in detail above.

[0528] 26 and 27 show an embodiment of a method comprising providing a third object 30 and attaching the third object 30 to the second object 2 by bonding the first object 1 to the second object 2 according to any embodiment of the method of bonding a first object 1 to a second object 2 .

[0529] In the embodiment shown in FIGS. 26 and 27 , the third object 30 includes a through hole 230 defining an opening 231 in a distal side of the third object 30 .

[0530] 26 and 27 include the optional feature of a region 232 surrounding the through-hole 230 that curves distally. Thus, the distal opening 231 is displaced in its entirety or at least in part with respect to the portion of the third body 30 that is not disposed proximate to the through-hole 230 toward the distal direction.

[0531] The method shown in Figures 26 and 27 includes the following steps: contacting the distal side 32 of the third object 30 with the proximal side 4 of the second object 2 and pushing the bending zone 232 into the second object 2. By doing so, the bending zone 232 creates a compression zone 201 in the area of ​​the second object 2 near the bending zone. Optionally, the third object 30 can be further pushed toward the second object 2, thereby forming a Figure 26b An integral compression zone 201 is shown.

[0532] In particular, the bending zone has mechanical stability so that it can withstand the loads generated during the step of pushing the bending zone 232 into the second object 2 .

[0533] In an embodiment of the method in which the bending region 232 is pushed into the second object 2, the method may include the further step of providing a pushing-down and pressing-down device. In other words, the third object 30 and / or the bending region 232 are pushed into the second object 2 not by pressure applied to the first object, but by pressure applied to the third object 30 using the pushing-down and pressing-down device.

[0534] The compressed region 201, located near the curved region 232, is further compressed during the subsequent step of pushing the protrusion 9 through the distal opening 231 and penetrating the second object 2. This creation of the compressed region 201 or the increase in density of the compressed region 201 has been described in detail. However, it is important to note that this creation or increase is not or is not solely the result of the liquefied material penetrating the second object 2, but rather the result of the protrusion 9 penetrating the solid portion of the second object 2 before the protrusion 9 liquefies. Portions of the protrusion 9 are converted into protruding portions 91 during the step of liquefying the thermoplastic material 3.

[0535] Thus, the combination of the compression formed by pushing the protrusion 9 into the second object and the compression formed by pushing the bending zone 232 into the second object 2 establishes the density distribution required to liquefy the thermoplastic material 3 of the protrusion 9 and to bond the first object 1 to the second object 2 during the step of applying mechanical pressing force and mechanical excitation.

[0536] However, it is conceivable to provide a third body 30 without a bending zone 232 and to design the protrusions in such a way that the compression zone 201 created by pushing the protrusions 9 into the second body 2 is sufficient to form the density distribution required to cause the thermoplastic material 3 to liquefy during the step of applying a mechanical pressing force and mechanical excitation.

[0537] exist Figures 26a to 26e In the embodiment, the third body 30 is a metal sheet, such as an aluminum sheet, which includes a selected feature of a region 232 surrounding the through hole 230 that is bent toward the distal side. In addition, the bent region 232 is designed to be elastically deformable. In particular, the edge 233 forming the distal opening 231 includes a notch 234 extending toward the proximal side, which means that the portion facing the third body 30 is not part of the bent region 232. The embodiment of the formed bent region 232 is Figure 26e Shown in.

[0538] In the embodiment comprising an elastically deformable bending zone 232, the diameter of the protrusion 9 is greater than the diameter of the bending zone 232. Thus, an elastic deformation in the sense of widening the bending zone 232 and the edge 233 is established. This is caused by Figure 26b Indicated by the two black arrows.

[0539] The following two effects are achieved by pushing at least a portion of the protrusion 9 through the through hole 230 ( Figure 26c ) caused by: First, the protrusion 9 penetrating the second object 2 affects the further local compression of the compression zone 201 formed by pushing the bending zone 232 to penetrate the second object 2. The protrusion 9 penetrating the second object 2 can cause the compression zone 201 to extend, especially in the distal direction. Second, the elastically deformed bending zone 232 causes a compressive force 239 on a portion of the protrusion 9. This compressive force Figure 26b Indicated by two black arrows.

[0540] During the step of applying mechanical compressive force and mechanical stimulation to the region where compressive force 239 is applied, compressive force 239 forms melted region 236 on protrusion 9. In other words, the thermoplastic material 3 of protrusion 9 liquefies due to compressive force 239 and the mechanical compressive force and mechanical stimulation applied in the corresponding step. In addition to the form-fitting connection established by the thermoplastic material having penetrated the material of second object 2, this also causes the bent region 232 to embed into protrusion 9, or more precisely, into protruding portion 91.

[0541] This means that according to Figures 26a-26e The method includes the further step of at least partially embedding the bending region 232 into the protruding portion 91.

[0542] Figure 26d A cross-sectional view of an exemplary embodiment of an attachment is shown, the attachment being based on an embodiment of a method comprising the further step of at least partially embedding the bending region 232 in the protruding portion 91 .

[0543] Figures 27a to 27c Another embodiment of a method is shown comprising the step of providing a third object with a bending zone 232 .

[0544] In the embodiment shown, the bending zone 232 is designed in such a way that the distal opening 231 is a radial opening about an insertion axis 235 along which the first object 1 moves relative to the second object 2 during the method of joining the first object 1 to the second object 2 .

[0545] The compression zone 201 is in turn created by pushing the bending zone 232 into the second object 2 .

[0546] 26 , the bending zone 232 is not designed to generate a compressive force 239 applied to the protrusion 9. However, the bending zone 232 and the protrusion 9 are designed so that the protrusion 9 is deformed toward the distal opening 231 during the step of pressing the protrusion 9 onto a portion of the bending zone 232.

[0547] 27 , the bending zone 232 comprises a portion arranged perpendicular to the insertion axis 235. This portion (and in particular the protrusion that deforms when pressed against said portion) allows the protrusion 9 to be directed towards the distal opening 231 during the step of pressing the protrusion 9 against said portion of the bending zone 232.

[0548] For example, the protrusion may include a deformation cavity 93 or a region with limited mechanical stability that facilitates deformation of the protrusion 9 in a predetermined direction.

[0549] Alternatively or additionally, the protrusion 9 may include a deformation surface 94 that may be designed in such a way as to establish a contact surface between the protrusion 9 and a portion of the bending region 232 that facilitates deformation of the protrusion 9 in a predetermined direction.

[0550] Figure 27d An example embodiment of such a protrusion 9 is shown. However, the protrusion 9 need not include a portion bent towards the distal opening 231 and / or a deformed cavity, as long as the portion of the curved zone 232 against which the protrusion is pressed has mechanical stability enabling it to absorb the mechanical energy applied in the method.

[0551] For example, the protrusion 9 may be rectilinear or conical and / or rotationally symmetrical about the protrusion axis 92 .

[0552] It is conceivable that the portion of the bend 232 that orients the protrusion 9 toward the opening 231 is not perpendicular (i.e., at 90 degrees) to the insertion axis 235, but rather is at an angle less than 90 degrees to the insertion axis, for example, between 30 and 80 degrees or between 50 and 80 degrees.

[0553] The deformation of the protrusion 9 towards the distal opening 231 may include a softening or partial softening of the protrusion 9 .

[0554] In the variant embodiment shown in Figures 26 and 27, the third object 30 is provided without the through hole 230 and the curved area 232 (if present). Rather, the through hole 230 and the curved area 232 (if present) are formed in a further step of the method. This further step is performed, in particular, after the step of bringing the distal side 32 of the third object 30 into contact with the proximal side 4 of the second object 2.

[0555] Figure 28 A first object 1 comprising a plurality of protrusions 9 is shown, wherein the total volume of all protrusions 9 satisfies the volume condition.

[0556] In many embodiments comprising a plurality of protrusions 9, the protrusions are arranged in a sub-region of the area formed by the distal side 14 of the second object. Said sub-region defines the base 211 of the protrusion region 90. Figure 28 In FIG. 2 , the base 211 is the area on the distal side 14 within the dotted line.

[0557] The total volume of the protrusion region 90 can be calculated from the base 211 and a value or formula corresponding to or close to the extension 25 of the protrusion 9 in the distal direction.

[0558] In many embodiments (but not all embodiments, such as Figure 15 、 16 , 21-23), the protrusions 9 have the same extension 25 in the distal direction. In other words: they have the same length. In this case, the value corresponding to the extension 25 of the protrusions 9 is their length.

[0559] The protrusions 9 within the protrusion area 90 are separated by gaps 27, which represent empty spaces. This space fills the volume of the protrusion area 90 that is not covered by the protrusions 9.

[0560] Figure 28 The volume condition satisfied by the exemplary embodiment shown in FIG and many other embodiments of the first object 1 is as follows: the volume of the protrusion 9 is half or less of the volume of the empty space. In other words, the mention of the protrusion 9 corresponds to 1 / 3 or less of the total volume of the protrusion area 90, such as 1 / 4, 1 / 5, or less than 1 / 5, such as 1 / 10.

[0561] FIG. 29 shows an embodiment of this method, wherein the (or one) high-density region 23 forms a proximal region of the second object 2 and the low-density region 22 is arranged distal to the high-density region 23 .

[0562] Additionally, the optional features of support 63 exist when first object 1 is bonded solely to second object 2 , or to an item to which second object 2 is or will be attached, or to an integral part of second object 2 .

[0563] Figure 29a The situation before the first object 1 is joined to the second object 2 is shown. Figure 29b The situation after the first object 1 is joined to the second object 2 is shown.

[0564] Figure 29a and 29b An embodiment of a second object 2 is shown in which the high-density region 23 can also be compressed. The double-headed arrow indicates the visible local compression of the high-density region 23 under the impact of the first object 1, which has been pushed through the high-density region 23 and has been anchored in the low-density region 22.

[0565] High-density region 23 is deformable, particularly compressible. This allows the first object 1 to be inserted without protruding from the proximal side 4 of the second object after bonding. Furthermore, this compression of low-density region 22 is in addition to the compression caused by protrusions 9 penetrating low-density region 22. Again, this compression zone 201 leads to effective liquefaction of thermoplastic material 3.

[0566] In the embodiment shown, thanks to said compression of the low-density areas 22 , the protrusions 9 do not need to be in contact with the supports 63 .

[0567] In the embodiment of FIG. 29 , the main body 7 of the first object 1 is simplified into a head.

[0568] 30 shows a cross-sectional view of a first object 1 bonded to another type of second object 2. According to this embodiment, a second object 2 is provided that features a proximal top layer 200 disposed on a low-density region 22 disposed above a high-density region 23 that imparts mechanical stability to the second object 2.

[0569] This construction, comprising a proximal top layer disposed over a low-density area 22 located over a high-density area 23, is found in articles that must be rigid and pleasant to the touch. Sometimes, such articles are also referred to as "soft touch" or articles having a "soft touch surface."

[0570] In an embodiment, the proximal top layer is leather, artificial leather or foil and the low density region 22 comprises or consists of foam or another porous and elastically deformable material.The high density region 23 may then be any type of support.

[0571] An example of a "soft-touch item" having the described structure is a dashboard, such as a car dashboard.

[0572] As an example, FIG. 30 shows a first object 1 as a display element coupled to a second object 2 as a control board having the previously described structure.

[0573] Figure 30a The provided second object 2 (control board) is shown, which means comprising a proximal top layer 200 and a low-density area 22 arranged above a high-density area 23. The provided second object 2 also comprises a feedthrough 207 designed to accommodate the first object 1 (display element) and, if present, a cable 209.

[0574] Figure 30b The first object (display element) is shown after being inserted into the second object 2 (control panel). The bonding method and the mechanism comprising the compressed area 201, the protruding portion 91 and the liquefied thermoplastic material 3 that has penetrated into the structure 10 of the low-density area 22 (e.g., foam) are the same as previously described.

[0575] As an alternative to integrally mounting the first object 1 (e.g. a display element), one could also conceivably first bond the connector 16 to the second object 2 and in a subsequent step bond the actual element to be attached to the second object 2. This embodiment is shown in dashed lines in FIG.

[0576] In this embodiment and again taking the example of a display element to be mounted to a control board, the first object 1 is a connector 16 and the display element is a third object 30 to be mounted via the first object 1 to a second object 2 , here representing a control board.

[0577] For example, the connector 16 comprises a connecting device element 15 for attaching a display element (third object 30 ) to the connector 16 , for example by a clamping mechanism.

[0578] The protrusion 9 can be designed to penetrate the proximal top layer 200 without previously perforating the proximal top layer 200. In particular, the protrusion 9 can be designed to penetrate the proximal top layer 200 without becoming fluidly perforated.

[0579] Needless to say, the first object 1 attached to the second object 2, characterized by the proximal top layer 200 disposed above the low-density region 22, can be any disclosed embodiment of the first object 1, such as a connector. In this case, the second object 2 does not include any features specifically for mounting a display element. For example, it does not include a feedthrough 207.

[0580] Figure 31 A cross-sectional view of a third object 30 is shown, which is attached to a second object 2 including a low-density area 22 via a first object 1 , wherein the first object 1 includes a head 212 and a protrusion 9 arranged distally of the head 212 .

[0581] The third object 30 may include pre-drilled holes, or the third object 30 and the protrusion 9 may be designed such that the protrusion can penetrate the third object 30 during the step of pressing the first object 1 towards the third object.

[0582] The head 212 is designed in such a way that a portion of the third object 30 is clamped between the head and the second object 2 , in particular the proximal side 4 of the second object 2 .

[0583] The bonding of the first object 1 to the second object 2 is again formed by the compression zone 201 formed during the step of pushing the protrusion 9 into the second object 2 .

[0584] Figure 32a and 32b An embodiment of such a method is shown, which comprises a step of providing an adhesive 240 before the step of pushing the protrusion(s) 9 into the second object 2 .

[0585] Figure 32a The situation is shown after providing the adhesive 240 on the near side 4 of the second object 2 .

[0586] In this embodiment, the first object 1 optionally features a retaining projection 213, which is arranged in the region of a lateral end of the main body 7. The retaining projection 213 projects from the distal face 28 of the main body 7 in the distal direction.

[0587] The retaining protrusions 213 are designed to prevent the adhesive 240 from being pressed laterally beyond the lateral extension of the first object 1, in particular the first object body 7. In other words: the retaining protrusions 213 are designed to prevent a reduction in the amount of adhesive that helps to bond the first object 1 to the second object 2 during the bonding process.

[0588] In particular, the retaining protrusions 213 prevent the region of the proximal side 4 of the second object 2 , which is the outer region after the bonding process, from being contaminated by the adhesive 240 .

[0589] The retaining protrusion 213 and the protrusion 9 may define a retaining opening 214 in which the adhesive accumulates.

[0590] Figure 32b The situation is shown after bonding the first object 1 to the second object 2 by employing a method comprising the further step of providing an adhesive 240 .

[0591] During the step of pressing the first object 1 into the second object 2, the adhesive 240 is pressed into the second object 2. As a result, a region 241 infiltrated with the adhesive 240 is formed at least around the protrusions 9. In this region 241, the material forming the low-density region 22 is reinforced by the adhesive. For example, the low-density region 22 includes fibers stacked together due to the presence of the adhesive.

[0592] Thus, the further step of providing adhesive 240 is another way of improving the quality, in particular the mechanical stability and reliability, of the first object 1 bonded to the second object 2 by this method.

[0593] Figure 33a and 33b Another example embodiment of a first object 1 that is a connector 16 is shown.

[0594] The connector 16 shown includes a protrusion area 90 having a plurality of protrusions 9 and a connection structure defining a connection location, which is defined with reference to all dimensions (x, y, z). In the embodiment shown, the connection mechanism is formed by a connecting pin 250 that is integral with the protrusions 9 and the body 7.

[0595] The connection mechanism (connecting pin in the embodiment shown) is in particular arranged transversely. This means that the connection mechanism 250 is not arranged symmetrically about the insertion axis 235, but is arranged eccentrically about the axis 235. The insertion axis is the axis along which the pressure is usually applied during the insertion process and along which the movement generated during the insertion process is at least predominantly carried out. The insertion axis 235 is usually a characteristic axis of the first object 1, such as an axis of rotation, a central axis and / or its coincidence with the protrusion axis. The latter may be the case when the first object 1 comprises a single protrusion 9 or a central protrusion 9. Thus, the axis is defined in particular by the overall shape of the protrusion and / or the first object 1.

[0596] Thus, the positioning of the connection point depends on the angle of rotation about the axis 235. Thus, when the connector is positioned relative to the second object 2 and anchored therein, not only the positioning but also the orientation has to be defined.

[0597] Examples of corresponding connecting structures may be, for example, a structure (e.g. a pin) extending away from the protrusion(s) in a defined direction, such as a pivoting member of a hinge or the like, a structure for clamping another object thereto, an anchor for a threaded connection, etc.

[0598] Figure 33a and 33b The connector 16 includes a plate-like body 7 defining a distally facing stop surface 12. Proximally, the connector includes a base wall 253 from which a connecting pin 250 extends transversely. The base wall is eccentrically arranged with respect to the axis 235. The connector also includes a plurality of reinforcing walls 254 extending perpendicularly to the base wall 253 and providing mechanical stability with respect to forces acting on the connecting pin.

[0599] After the process of applying pressure until the stop surface 12 comes into contact with the proximal side 4 of the second object 2 , the stop surface facing the distal side defines the z position of the connecting structure.

[0600] Figure 33a and 33b The connector 16 in the embodiment of FIG. 1 may be, for example, a bracket of a rear cargo panel of a car.

[0601] The welding electrode 20 for anchoring the connector can be designed to conform to the shape of the connector. In particular, Figure 33a As shown, the connector may be shaped to act proximally on the body 7 by engaging between the reinforcing wall 254 and the base wall 253. Additionally or alternatively, it is also possible to provide a protruding flange 255 of the connector 16, such as Figure 33a An arrangement in which the welding electrode engaging between the walls acts directly on the body 7 (although if necessary with recesses for the reinforcing wall(s)) has the characteristic that pressure and vibrations (more generally mechanical excitation) are coupled directly into the protrusion.

[0602] In embodiments including a connection portion, the location and / or orientation of the connection portion is dependent upon the orientation of the connector about its axis 235, and it may be necessary to guide the orientation of the connector during the anchoring process because the connector may be subject to some uncontrolled torsional motion during insertion due to vibration input (or more generally mechanical excitation). Figure 33a and 33b In an embodiment, the base wall 253 and / or the reinforcing wall 254 may be used together with a corresponding shape of the welding pole, whereby the orientation of the welding pole defines the orientation of the connector.

[0603] Figure 33a and 33b The exemplary embodiment also includes optional features such as a cutting structure 252 that is designed to penetrate the proximal top layer.

[0604] The embodiment of FIG. 33 (for example, Figure 7 ) comprises adopting a welding electrode adapted to the geometry of the first object 1 as a connector. This is not always necessary. It is conceivable that in an embodiment of the first object 1 as a connector, the body 7 forms a substantially flat coupling surface for a universal welding electrode.

[0605] The connector may include at least one machined abutment protrusion. The number and / or arrangement and / or dimensions of the protrusions 9 are such that the connector can be held in a desired position relative to the second object upon initial application of mechanical compressive force and, if appropriate, mechanical actuation. This protrusion(s) and the protrusions together can stabilize the connector in an upright position when the connector contacts the proximal side of the second object. In other words, the connector's positioning is well-defined and stable.

[0606] Such abutment protrusions will collapse or melt in the subsequent process.It is not necessary to penetrate into the volume of the second object.

[0607] In addition to stabilizing the connector during the initial stages of the process, it also prevents undesirable bending when the body 7 has a large amount of lateral extension.

[0608] Figures 34-39 Various exemplary embodiments of the raised area 90 of the first object 1 and the device are shown, respectively.

[0609] exist Figure 34 In the exemplary embodiment shown, the protrusion 9 comprises a protrusion axis 92 which extends non-parallel to the normal of the distal side 28 of the main body 7 of the first object 1 .

[0610] A projection axis 92 extending non-parallel to the normal direction defines a direction along which the projection 9 is deformed during the method of any of the disclosed embodiments.

[0611] A further effect of the projection axis 92 not extending parallel to the normal of the distal side 28 of the main body 7 of the first object 1 is that the length of the projection is greater than the extension 25 of the projection in the distal direction.

[0612] exist Figures 34-39 The exemplary embodiment of the first object 1 shown in FIG. 1 shows at least the following features:

[0613] Functional area 50. Figure 38 and 39 In the embodiment of FIG. 5 , the functional area is provided by a distal opening of a through hole extending from the proximal side 29 to the distal side 28 of the main body 7 of the first object 1 .

[0614] The first object 1 comprising the through hole may be used to stabilize or fix the edge of the formed feedthrough, for example to penetrate into the second object 2 .

[0615] • Gaps 27 between the protrusions 9, wherein the volume of the gaps and the weight of the protrusions have the ratios described above.

[0616] The extension 25 of the protrusion 9 in the distal direction and the thickness 26 of the protrusion 9 are such that the ratio between said extension 25 and said thickness 26 is as described above, which means that this ratio is at least 1, in particular between 1 and 5, for example between 1.5 and 4 or between 2 and 3.

[0617] Figures 40-43 A perspective view of various embodiments of the first object 1 and the device is shown respectively.

[0618] In addition to the features regarding the raised area 90 , the individual connecting device elements 15 of the connecting mechanism are also shown. Said connecting device elements are arranged on the proximal side 29 of the main body 7 of the first object 1 .

[0619] The embodiment shown includes a connection point 51 at which the connecting device element 15 is coupled to the first object 1. In the embodiment shown, the connection point 51 includes and is limited to a portion of the proximal side of the body 7 of the first object 1 that is opposite the functional area 50 arranged on the distal side 28 of the body 7 of the first object 1.

[0620] Figure 40 The connecting device element 15 of the first object 1 shown in FIG. 1 is suitable for attaching a cable and / or a wire to the first object and thereby to a second object.

[0621] Figure 42 The connecting device element 15 of the first object 1 shown in the figure is an example of a connecting element suitable for screwing an item into the first object and thereby into the second object. The connecting element shown may comprise a longitudinal opening through the distal side 28 of the main body 7 of the first object 1.

[0622] Figure 42 The connecting device element 15 of the first object 1 shown in FIG. 1 is suitable for attaching a plate-shaped and / or sheet-shaped item to the first object and thereby to a second object.

[0623] Figure 43 The connecting device element 15 of the first object 1 shown in FIG. 1 is an example of a connecting device element for a clamping solution.

[0624] Figure 34-43 The first object 1 shown in FIG is joined to the second object 2, for example, by using a welding electrode 20, which is usually applied to the portion of the proximal side 29 of the first object 1 that is not covered by the connecting device element 15 or any element of the connecting mechanism. In addition, the mechanical excitation (here, mechanical oscillation) is preferably applied along an axis 8 that is angled with respect to the proximal side 29, in particular extending along its normal.

[0625] In this case, during the step of applying the mechanical pressing force and mechanical excitation, the output surface 21 of the welding electrode 20 preferably extends over an area of ​​the proximal side 29 of the first object 1 that corresponds to the opposite area covered by the protrusions 9 on the distal side 28 of the first object 1. For example, the area in contact with the output surface 21 covers at least 80% of the area covered by the protrusions on the distal side 28 of the first object 1. For example, the area covered by the protrusions 9 may extend over an area that is 0.8 to 2 times, in particular 0.8 to 1.5 times, 0.8 to 1.2 times, or 0.8 to 1 times, the area covered by the protrusions 9. In other words, the radial extent of this area of ​​the proximal side 29 is at least 80% of (and in particular, greater than) the radial extent of the area covered by the protrusions on the distal side 28 in any radial direction.

[0626] The coupling-out surface 21 may protrude from the main body 7 of the first object 1 .

[0627] Figures 44-49 An exemplary embodiment of the first object 1 is shown, which comprises a device capable of preventing the generation of natural oscillations within the first object body 7 of a strength that could be destructive to the first object body 7 .

[0628] according to Figure 44 The embodiment comprises a damping element 52, which is arranged on the distal side of the first object body.

[0629] The damping element 52 is in contact with the proximal side surface 4 of the second object 2, or, as the case may be, with the proximal side surface 31 of the third object 30, during the method of bonding the first object 1 to the second object 2. Thus, the natural oscillation generated in the first object body 7 during the step of applying mechanical excitation to liquefy the thermoplastic material 3 can be damped due to the physical contact between the damping element 52 and the second object 2 (or, as the case may be, the third object 30).

[0630] In the embodiment shown, the damping element 52 also comprises a thermoplastic material. In other words, the damping element 52 is not only capable of damping the natural oscillations, but is also capable of strengthening the bond between the first object and the second object (or the third object).

[0631] according to Figure 45 and 46 The embodiment of includes a variety of distinct raised areas 90 designed to minimize the mechanical excitation energy required to liquefy the thermoplastic material.

[0632] Figure 45 and 46 Also shown are a set of protrusions capable of adjusting the natural oscillation frequency of the first body 7 away from the frequency applied to cause the liquefaction of the thermoplastic material.

[0633] At least one of the raised areas 90 may also be arranged to function as a damping element 52, such as Figure 45 and 46 However, it is not mandatory that one of the plurality of raised areas is designed and arranged as a damping element 52 .

[0634] Figure 47 and 48 Shown is a first object 1 comprising a fixing element 1 . 1 designed to be bonded to a second object 2 by means of a method according to the invention and a connecting element 1 . 2 designed to be bonded to the fixing element 1 . 1 .

[0635] The fixing element 1.1 comprises a fixing element connecting mechanism 110 and the connecting element 1.2 comprises a connecting element connecting mechanism 120, which are conformable to each other in such a way that a bond can be established between the fixing element 1.1 and the connecting element 1.2.

[0636] In the embodiment shown, the fixing element connection means 110 is a through hole in the body 7 . 1 of the fixing element 1 . 1 and the connection element connection means 120 is a protrusion having a diameter adapted to the diameter of the through hole.

[0637] The protrusion 9 comprises a thermoplastic material and is designed in such a way that it can be bonded to the second object 2 after being pushed through a through hole in the body 7 . 1 of the fixing element 1 . 1 .

[0638] Additionally or alternatively, the projection 9 comprises a thermoplastic material and is designed in such a way that it can be welded to the thermoplastic material of the fixing element 1 . 1 , in particular the thermoplastic material of the projection 9 designed for bonding the fixing element 1 . 1 to the second object 2 by a method.

[0639] One can also envisage other mechanisms for joining the connecting element 1 .2 to the fixing element 1 .1 , such as clamps, clamps and / or snap locks.

[0640] Figure 49 The fixing element 1 . 1 of the first object 1 is shown in detail, comprising the fixing element 1 . 1 and the connecting element 1 . 2 .

[0641] The body 7.1 of the fixing element 1.1 and the corresponding connecting element 1.2 consists of a thermoplastic material. The fixing element 1.1 includes a fixing element energy director 111, and the connecting element 1.2 may include a coupling element energy director. This energy director defines a region where the thermoplastic material of the fixing element 1.1 and the connecting element 1.2 liquefies during the further steps of applying mechanical compressive force and mechanical stimulation.

[0642] This further step results in a connection (in particular welding) between the fixing element 1 . 1 and the connecting element.

[0643] In particular, said further step is applied after the step of applying a mechanical pressing force and mechanical actuation causing liquefaction of the thermoplastic material of the protrusion(s). This means that said further step is applied after bonding the fixing element 1 . 1 to the second object 2 .

[0644] The method comprising the two steps of applying a mechanical pressing force and a mechanical excitation (applying a mechanical pressing force for bonding the fixing element 1.1 to the second object 2 and applying a mechanical excitation for bonding the connecting element 1.2 to the fixing element 1.1) has at least one of the following advantages:

[0645] the energy acting on the portion of the first object 1 that abuts against the element 15 of the connecting device can be reduced;

[0646] The coupling-out surface 21 of the welding electrode 20 can be adapted to the shape of the fixing element 1 . 1 and / or the shape of the connecting element 1 . 2 ;

[0647] Any problems based on the fact that the fixed oscillation frequency of the first object body 7 is close to the mechanical excitation frequency required during bonding of the first object 1 (this means the fixing element 1 . 1 ) to the second object 2 can be avoided.

[0648] Figure 50 and 51 Another method of securing the third object 30 to the second object 2 via the first object 1 is shown.

[0649] According to this method ( Figure 50 ), the third object 30 is bonded to the proximal side of the first object body 7.

[0650] Designed for use according to Figure 50 and 51 The first object 1 in the method comprises a proximal side 29 extending over a large area. Figure 51 There is shown such a first object 1. In particular, the first object body 7 forms an area to which the third object 30 can be fixed.

[0651] Additionally, it is designed to Figure 50 and 51 The method in which the first object 1 may include a method for preventing reference to Figures 44-48 Any of the characteristics of destructive natural oscillations that exist.

[0652] The first object 1 in any of the above-described embodiments (e.g. Figure 1-5 , 14, 16, 17, 20, 26a, 28, 29a, 31 and 34-43) can be used to attach the third object 30 to the second object 2.

[0653] Specifically, the third object 30 may be a sheet material, such as a metal sheet.

[0654] The attachment of the third object 30 may comprise at least a partial compression of the second object 2 in such a way as to develop a critical density and / or a critical compressive strength.

[0655] Figure 52 A cross-sectional view showing the structure and design of a first object 1 , a second object 2 and a sheet material to be fixed to the second object 2 by the first object 1 .

[0656] The sheet shown comprises through holes 230 , the shape and number of which are adapted to the protrusion(s) 9 of the first object 1 .

[0657] For example, the protrusion 9 may be as follows Figure 1 and 5 In this case, the sheet may include through holes 230 in the form of longitudinal slits.

[0658] For example, the first object 1 may include Figure 5 、 28 , 34, 36 and 37. In this case, the sheet may include through-holes 230 having a circular or rectangular footprint.

[0659] For example, the first object 1 may include Figure 35 The raised area 90 is shown. In this case, the sheet may include through holes 230 in the form of annular slits.

[0660] The through hole 230 enables the relative position of the sheet material to be adjusted with respect to the first object 1. In the case where the first object 1 comprises a protrusion area 90 having a plurality of protrusions 9 arranged along a line, the sheet material may comprise a through hole 230 in the form of a longitudinal slit on each line of the protrusions 9.

[0661] Figure 53 A cross-sectional view showing another structure and design of a first object 1 , a second object 2 and a sheet material, wherein the sheet material is fixed to the second object 2 via the first object 1 .

[0662] According to this example arrangement, the first object 1 may include at least two protrusions 9 and the corresponding method includes the steps of arranging the first object 1, the second object 2 and the third object 30 so that at least one protrusion 9 is arranged to exceed the radial end of the sheet and at least one protrusion 9 is in contact with the proximal end of the third object 30.

[0663] The third object 30 may include a reference Figure 52 For the type of through-hole 230 described, the first object 1 may be arranged relative to the second object such that the at least one protrusion engages with the through-hole 230 .

[0664] In the embodiment shown, the third body 30 comprises a flange 237 designed to be positioned on the second body and attached to the second body via the first body.

[0665] Specifically, the first object 1 may be, for example, Figure 1-5 , 20, 28 and 34-43.

[0666] exist Figure 53 In the embodiment, the third object 30 is a metal sheet. If the third object 30 is a metal sheet, the metal sheet is or can be heated during the method. This causes local melting of the second object 2, leading to a further increase in the density of the low-density region 22 and further strengthening thereof. In other words, the second object 2 can be locally converted into an adhesive material.

[0667] Figure 54a and Figure 54bThere can be seen a method for fixing a third object 30 , which is a metal sheet without through holes 230 for the protrusion(s) 9 , to the second object 2 .

[0668] The method comprises the following steps:

[0669] Arrange the first object 1 , the second object 2 and the metal sheet opposite one another so that the proximal side 31 of the metal sheet is in contact with the protrusion 9 and so that the distal side 32 of the metal sheet is in contact with the second object 2 .

[0670] Pressing the first object 1 to the metal sheet so that the first object 1 and the metal sheet are vibrationally coupled to each other.

[0671] Apply mechanical vibration to the first object 1 and increase pressure to deform the metal sheet and penetrate the second object 2.

[0672] The pressure is further increased until the protrusion(s) 9 penetrate the metal sheet. In other words, a penetration area 260 is formed in the metal sheet.

[0673] The thermoplastic material that has penetrated the metal sheet is liquefied in the compression zone 201 of the second object and / or the liquefied thermoplastic material is pressed within the compression zone 201 .

[0674] This method embodiment is generally applicable to sheet metal. However, its application to sheet metal offers the advantage that the sheet metal heats the second object 2 during the process. This causes local melting of the second object 2 (melting zone 261), which in turn leads to a further increase in the density of the compressed zone 201 and a further strengthening of the low-density region. In other words, the second object 2 can be locally converted into an adhesive material.

[0675] Figure 55 Shows the Figure 54a and 54b An exemplary embodiment of a first object of the method. The illustrated embodiment comprises:

[0676] The first row of protrusions and the second row of protrusions. In the embodiment shown, the first row of protrusions and the second row of protrusions have the same length. In addition, the protrusions are tapered.

[0677] The first area 263 and the second area 264 on the distal side of the first object 1 are offset in the distal direction. In the embodiment shown, the second area 264 (central area) is located further distal to the first area 263 (area between two rows of protrusions).

[0678] The further distal region is arranged in particular to damp natural oscillations during the method, in particular in the final phase of the method when the energy coupled into the object is highest.

[0679] Channels for material flow.

[0680] like Figure 55 The illustrated first object may help to avoid destructive stationary oscillations and destructive deformations of the third object 30 , particularly if the third object is a metal sheet.

[0681] Figure 56 A cross-sectional view of the basic configuration of the first and second objects showing an embodiment of a method in which a welding electrode 20 is applied to a second object 2 is shown.

[0682] In the example arrangement shown, the first object 1 is an item to which the protrusion 9 is connected. One can envision configurations in which the near side of the first object 1 is not or not easily accessible. For example, the item may be a vehicle body part.

[0683] In particular in such a configuration, the second object 2 can be arranged opposite the projection 9 such that the projection 9 is in contact with a portion of the second object 2 which is to be at least partially penetrated by the projection 9 during the method.

[0684] exist Figure 56 In the embodiment shown, the second object 2 is a cover comprising a low-density first area 204 forming an opening arrangement layer and a low-density second area 205 in which a form-fitting connection is to be formed between the first object and the second object. Figure 56 (as well as Figure 57a and 57b ) is not mandatory for the method / application shown in ). The second object 2 may have a more complex structure or it may be homogeneous.

[0685] Figure 57a and 57b An example application of an embodiment of the method is shown in which a welding electrode 20 is applied to a second object 2 .

[0686] Figure 57a The arrangement of the first object 1 , the second object 2 and the welding electrode is shown before the step of applying a mechanical pressing force and a mechanical stimulation capable of liquefying the thermoplastic material.

[0687] Figure 57b The situation after the first object 1 is joined to the second object 2 is shown.

[0688] Figure 57a and 57b It shows:

[0689] A second object 2 , which is a covering of the first object 1 , for example a part of a vehicle body, wherein the covering is conformable or can be conformable to the first object 1 .

[0690] A plurality of protrusions 9 , which are arranged on the first object 1 in such a way that the cover 2 is securely fixed to the first object 1 .

[0691] An article 2 is arranged on the first body 1 so that the bonding site on the proximal side 4 of the article 2 is in contact with the protrusion.

[0692] A welding electrode 20 , which is applied locally and sequentially to the area of ​​the distal side 14 of the object 2 corresponding to the location of the protrusions 9 .

[0693] The welding electrode is applied to the article 2 until it has reached the desired end position relative to the first body 1 .

[0694] Figure 58 A variant of the method is shown in which the second object 2 is arranged between the first object 1 and the welding electrode 20 .

[0695] According to this variant, any force used to drive the protrusion(s) 9 to penetrate the second object 2 is applied to the first object 1 (indicated by the arrow below the first object 1).

[0696] The welding electrode 20 is in contact with the distal side 14 of the second object 2 and couples mechanical oscillations into the second object 2. The welding electrode also serves as a support for the second object 2, but it does not actively push the second object 2 towards the first object 1.

[0697] This arrangement of applying the welding electrode to the second object 2 and any pushing force to the first object 1 has the effect of forming a compression zone 201 around the protrusion(s), wherein the compression of the distal side 14 of the second object 2 remains small.

[0698] Figure 59 Two stress-strain curves (A and B) are shown which represent experimental results leading to the surprising discovery that various non-stick materials are suitable for bonding methods that rely on liquefaction of thermoplastic materials by applying mechanical pressing forces and mechanical excitation, in particular vibration.

[0699] The relative behavior of stress-strain curves A and B illustrates the effect of the varying surface through which the load is applied to the material. The test indenter of curve B has a greater surface area in contact with the material than the test indenter of curve A.

[0700] Figure 59 A first region where the observed stress and strain relationship is approximately linear, an observed transition region, and a second region where the observed stress and strain relationship is approximately linear are shown.

[0701] In different regions of linear correlation, the straight line close to the linear correlation is represented by a dotted line.

[0702] The strain ε at the intersection of the slope of the first region of approximately linear correlation and the slope of the second region of approximately linear correlation c is a characteristic value for the stress-strain behavior of a material. Said characteristic value can be used to define the minimum compression required in embodiments of the method in which a form-fitting connection is to be formed in low-density areas.

Claims

1. A functional component having at least one connector integrated therein for attachment to an article (2), the functional component being part of a vehicle component or a vehicle body component, wherein the at least one connector extends between a proximal end (5) and a distal end (6) and comprises a connector body (7) forming a proximal side (29) and a distal side (28), and the at least one connector comprises a thermoplastic material (3) in a solid state, wherein the at least one connector comprises a plurality of protrusions (9) extending from the distal side (28) and spaced apart from each other, and the protrusions (9) are on an outer side The thermoplastic material (3) is included in the place, wherein the at least one connector includes a structure, which is designed and arranged to promote local compression within the article when forced to penetrate the article, wherein the increase in compression strength is suitable for liquefying the thermoplastic material, and the structure is determined by the shape of barbs (24) arranged at the distal end of the protrusion (9), wherein the barbs (24) each include at least two prongs with a V-shaped, U-shaped or W-shaped recess therebetween, so that the functional component is suitable for being connected to the article (2) at a connection location (13) in the form of mutually separated connection points.

2. The functional component according to claim 1, wherein the distal side forms a stop surface (12).

3. Functional component according to claim 1, wherein the protrusion (9) consists of the thermoplastic material (3).

4. A functional component according to claim 1, wherein the connector includes a first type of protrusion (33) and a second type of protrusion (34), the first type of protrusion (33) being designed to be anchored in the article (2), and the second type of protrusion (34) being designed to be anchored in another object (30) different from the article (2).

5. Functional component according to claim 4, wherein the further object (30) comprises a covering layer. The functional component according to claim 5 , wherein the covering layer is a metal sheet. The functional component according to claim 6 , wherein the metal sheet is a foil.

8. The functional component according to claim 1, wherein the protrusion (9) is arranged in a protrusion area (90) of the distal side (28) of the connector body (7), wherein a base-shaped transition portion is arranged between the distal side (28) and the protrusion.

9. The functional component according to claim 1, wherein the top end of the protrusion (9) comprises a structure in the form of one or more notches, wherein the notches comprise sharp-angled openings.

10. The functional component according to claim 1, wherein the top end of the protrusion (9) comprises a pyramid-like shape.

11. A use of a functional component according to claim 1, for penetrating a rigid covering layer (200) of an article (2), wherein the article further comprises a low-density area, the low-density area being arranged on a side of the rigid covering layer (200) away from a distal side (28) of the at least one connector and being separated from the rigid covering layer (200), and the at least one connector further penetrating into the low-density area to achieve bonding with the article (2).

12. Use according to claim 11, wherein a compression zone (201) is formed in the low-density area (22).

13. A use of a functional component according to claim 1 for connecting an item (2) having a low-density area (22) to another object (30), wherein the other object (30) includes a pre-drilled hole, and the pre-drilled hole is designed to clamp the other object between the item (2) and the at least one connector by pressing the distal side (28) of the at least one connector against the proximal side of the other object (30), so that the protrusion of the at least one connector penetrates the other object (30).

14. Use according to claim 13, wherein a compression zone (201) is formed in the low-density area (22).

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