Method for joining three components and connected system

Abstract

Method for joining three components (1, 2, 3) which has the following features: - Positioning the components (1, 2, 3) such that connecting surfaces (1.1, 2.1.1) of the first and second components (1, 2) and contact surfaces (1.2.1, 3.1) of the first or second component (1) and the third component (3) are opposite each other; - Material-bonded joining of the first and second components (1, 2) by means of the joining surfaces (1.1, 2.1.1) and deformation of the first or second component (1) in a region (1.2) of its at least one contact surface (1.2.1) in contact with the corresponding contact surface (3.1) of the third component (3), each by means of a common joining force F, wherein the first and second components (1, 2) as well as the first or second component (1) and the third component (3) are moved relative to each other along a common joining axis (4) and the third component (3) is fixed parallel to the joining axis (4) after the deformation of the first or second component (1) by means of the first and second components (1, 2), - characterized in that the components to be joined in the aforementioned manner do not allow the second component to pass through the third component.

Description

[0001] The present invention relates to a method for connecting three components and a connected system.

[0002] Such methods for connecting three components and connected systems are already known in numerous variations from the prior art.

[0003] For example, DE 10 2005 000 160 B4 discloses a method for the positive joining of two components, in which a first and a second component to be positively joined are positioned relative to each other and the first component is welded to a third component using a transmission welding process, wherein, by means of an infeed movement of the third component during the welding process relative to the first component, material from plastically deformable areas of the first component is displaced in such a way that the displaced material creates a positive connection between the first and the second component.

[0004] Furthermore, a method for welding a first component to a second component is known from DE 102 56 254 A1, wherein this method is characterized in that at least one stop, which limits a relative movement of the components to each other when connecting the two components by means of laser radiation, simultaneously fixes a third component.

[0005] This is where the present invention comes in.

[0006] The present invention is based on the objective of enabling the connection of three components using simpler means.

[0007] This problem is solved by a method having the features of claim 1 and a connected system having the features of claim 6. The dependent claims relate to advantageous embodiments of the invention.

[0008] A significant advantage of the invention lies particularly in the fact that the joining of three components is simplified from a manufacturing perspective. For example, the invention eliminates the need for transmission welding of the second component to create a positive-locking connection with the third component. Thus, an additional transmission welding device is not required. Furthermore, the three components that can be joined by the invention can be freely selected within certain limits with regard to type, material, dimensions, and relative arrangement to one another. According to the invention, if it is not possible to pass the second component through the third component...

[0009] In principle, the joining force and other process parameters can be freely selected within wide, suitable limits. Advantageously, the joining force is controlled or regulated as a function of a reference variable, where the reference variable is a quotient formed from a joining path and a joining time. This is particularly advantageous for material-bonded connections between the first and second components, such as welds. By using the aforementioned quotient as the target variable, a relatively high degree of independence from the transparency and / or absorption of the first and second components to be joined, for example, plastic parts, is achieved. By selecting the joining force as the control variable, a relatively uniform fixation strength of the third component, for example, a printed circuit board, can be achieved, regardless of the dimensions of the third component along the common joining axis.

[0010] A particularly advantageous further development of the aforementioned embodiment provides that the joining force is controlled or regulated in such a way that the ratio remains essentially constant throughout the entire joining time. In this way, for example in a material-bonded connection between the first and second components created using a laser welding process, a molten metal flow into the weld bead that is essentially constant throughout the entire joining time is enabled, thus ensuring a constant dissipation of excess energy from the weld zone.

[0011] For this purpose, the joining force can be adjusted as a control variable by means of a drive, for example an electric servomotor, during the joining process such that a joining path-joining time curve corresponding to the weld exhibits an essentially proportional profile. Due to the uniform molten metal flow into the weld bead, it is possible to keep the temperature distribution and thus the weld strength constant in the weld zone, i.e., in the area of ​​the joining surfaces of the first and second components. This effectively prevents a decrease in weld strength depending on the component tolerances of the three components being joined. The required weld quality, i.e., the strength or the tightness of the weld, is ensured independently of the joining path and joining time.

[0012] Another particularly advantageous embodiment of the inventive method according to the two latter embodiments provides that the quotient is automatically determined in an initial phase of the joining process and used as a guide parameter for the subsequent remainder of the joining process. This eliminates the need to start the joining process with a quotient value that is predetermined before the welding process. Consequently, the setup time can be reduced. Furthermore, it allows the quotient to be adapted to the specific conditions of the components to be joined.

[0013] In principle, the material-bonded connection between the first and second components can be freely selected within wide suitable limits in terms of type, material, dimensions, and arrangement. As already illustrated above, the material-bonded connection is advantageously achieved through welding, particularly laser welding. Welding enables durable and leak-proof connections with a long service life. Furthermore, welding processes are readily automatable. Laser welding is particularly advantageous because it is contactless and also suitable for complex geometries of the components to be joined. Moreover, compared to other welding processes, laser welding results in only minimal thermal distortion.

[0014] An advantageous embodiment of the connected system according to the invention provides that the first component and / or the second component has / has at least one first projection, wherein the free end of the first projection is designed as one of the first connecting surfaces. By means of the first projection, the connecting surface formed thereon can be easily adapted to the requirements of the material-bonded connection, independently of the rest of the first and / or second component. This is particularly advantageous if, for example, the connecting surfaces require a higher-quality surface treatment for the material-bonded connection.

[0015] A further advantageous embodiment of the connected system according to the invention provides that the first component or the second component has at least one second projection, wherein the free end of the second projection of the first or second component is designed as a contact surface. This allows the first or second component to be adapted to the requirements of the individual case in the area of ​​its at least one contact surface in a structurally simple manner. For example, the second projection can be made of a material different from the rest of the first or second component, such as a metal or another plastic, and connected to this rest in a suitable manner known to those skilled in the art. Furthermore, it enables the second projection to be dimensioned and designed advantageously for the respective application.For example, the cross-section of the second projection can be reduced towards its free end to allow for controlled deformation of the second projection with less resistance. Furthermore, this approach makes it easy to adapt the contact surface formed on the second projection to the specific requirements of each application, independently of the rest of the first and / or second component. A combination of different surface geometries, such as circular or rectangular shapes, is also conceivable for the contact surface.

[0016] An alternative further development of the aforementioned embodiment provides that the first component has at least one second projection, wherein the free end of the second projection of the first component is designed as a contact surface and a third projection of the second component is arranged in the area of ​​the third component facing away from the second projection when the first component is deformed and acts as a support for the third component, or that the second component has at least one second projection, wherein the free end of the second projection of the second component is designed as a contact surface and a third projection of the first component is arranged in the area of ​​the third component facing away from the second projection when the second component is deformed and acts as a support for the third component.This also ensures a defined contact between the first or second component and the third component, and thus good force transmission during the deformation of the first or second component in the area of ​​its at least one contact surface in contact with the corresponding contact surface of the third component.

[0017] A further advantageous embodiment of the connected system according to the invention provides that the first component and / or the second component has at least a fourth projection, wherein the free end of the fourth projection is designed as a stop and limits a joining path along the joining axis when the connected system is joined. In this way, limiting the common joining path for producing the material-bonded connection between the first and second components and the deformation of the first or second component in contact with the third component is achieved with structurally simple means.

[0018] The invention is explained in more detail below with reference to the attached, roughly schematic drawing. This drawing shows: Fig. 1 an embodiment of a connected system according to the invention before the connection, in a partial view in a side section view, at the end of positioning the components; Fig. 2 the embodiment in a with Fig. 1 comparable representation, during the joining process; Fig. 3 a joining path-joining time diagram corresponding to the inventive method carried out by means of the exemplary embodiment and Fig. 4 a joining force-joining time diagram corresponding to the inventive method carried out using the exemplary embodiment.

[0019] In Fig. Figure 1 shows an embodiment of a connected system according to the invention before connection. The connected system comprises three interconnected components, namely a first component 1, a second component 2, and a third component 3. The first and second components 1 and 2 are each designed as a housing half made of plastic. The third component 3 is designed as an electrical circuit board, which is received in the housing formed by the first and second components 1 and 2. Fig. 1. The three components 1, 2 and 3 are not yet connected to each other.

[0020] For the material-bonded connection of the first and second components 1, 2, the second component 2 has a first projection 2.1, the free end of which 2.1.1 is designed as a connecting surface. Corresponding to the connecting surface 2.1.1 of the second component 2, the first component 1 has a connecting surface 1.1. Both connecting surfaces 1.1 and 2.1.1 are material-bonded to each other in a welding process designed as a laser welding process, as described below. Furthermore, the first component 1 has a second projection 1.2, which interacts with a surface 3.1 of the third component 3, designed as a contact surface, as described below. For this purpose, the second projection 1.2 is designed as a conical dome, which has a larger circular cross-section at its root facing the rest of the first component 1 than at its free end 1.2.1 facing the surface 3.1 of the third component 3.The free end 1.2.1 of the second projection 1.2 is designed as a contact surface for contacting the corresponding contact surface 3.1 of the third component 3. The conical dome 1.2 is, as shown in . Fig. As can be seen, it is formed from the first component 1.

[0021] In order for the third component 3 to be fixed parallel to a common joining axis between the first and second components 1, 2 after the joining of the connected system, i.e., after the creation of the material-locking connection between the first and second components 1, 2 and after the deformation of the second projection 1.2 of the first component 1, the second component 2 in the present embodiment has a third projection 2.3 which, during the deformation of the second projection 1.2 of the first component 1, is arranged in the area of ​​the third component 3 facing away from the second projection 1.2 and acts as a support for the third component 3. The joining axis is in Fig. 1 symbolized by a double arrow 4.

[0022] Furthermore, the first component 1 has a fourth projection 1.4, wherein the free end of the fourth projection 1.4 is designed as a stop and limits the common joining path s along the joining axis 4 for the production of the material-locking connection and the deformation of the second projection 1.2 of the first component 1 when connecting the connected system.

[0023] The inventive method for connecting three components is described below using the connected system according to the exemplary embodiment as an example, as well as the Fig. 1 to 4 explained in more detail.

[0024] First, the three components 1, 2, and 3 are positioned relative to each other such that the corresponding connecting surfaces 1.1 and 2.1.1 of the first and second components 1 and 2, as well as the corresponding contact surfaces 1.2.1 and 3.1 of the first component 1 and the third component 3, are opposite each other. See also Fig. Figure 1 shows the final position after positioning the components 1, 2, and 3 to be joined, for the subsequent connection of the components 1, 2, and 3. As shown in Figure 1, the final position after positioning the components 1, 2, and 3 to be joined is shown. Fig. As is clearly evident in Figure 1, the two connecting surfaces 1.1 and 2.1.1 are in contact with each other, while the two contact surfaces 1.2.1 and 3.1 are spaced apart. This positioning of the two connecting surfaces 1.1 and 2.1.1 and the two contact surfaces 1.2.1 and 3.1 relative to each other is not mandatory, but advantageous. For example, it is also conceivable that the two connecting surfaces 1.1 and 2.1.1 are initially positioned at a distance from each other, or that the two contact surfaces 1.2.1 and 3.1 are in contact with each other in this position.

[0025] In the next step, components 1, 2, and 3 are moved relative to each other along the common joining axis 4 such that the connecting surfaces 1.1 and 2.1.1 and the contact surfaces 1.2.1 and 3.1 are moved towards each other by means of a common joining force F acting along the joining axis 4. For this purpose, the second component 2 is fixed by means of a holder (not shown), and the first component 1 is moved towards the second component 2 and the third component 3, which is placed on the third projection 2.3 of the second component 2, by means of a positioning device (also not shown). See [reference to be added]. Fig. 1 in conjunction with Fig. 2.

[0026] As from Fig. As can be seen and already explained in Figure 1, the joining surfaces 1.1 and 2.1.1 for the material-bonded connection of components 1 and 2 are already in contact, so that the laser welding process begins in a manner known to those skilled in the art using a laser welding device (not shown). In this process, the two components 1 and 2 are melted in the area of ​​the joining surfaces 1.1 and 2.1.1, so that the first component 1 can move further towards the second and third components 2, 3 under the influence of the joining force F.

[0027] As soon as the two contact surfaces 1.2.1 and 3.1 come into contact for the deformation of the second projection 1.2 of the first component 1, the deformation of the second projection 1.2 of the first component 1 begins in parallel with the material-bonded joining of components 1 and 2. In this process, the second projection 1.2 of the first component 1 comes into force-transmitting contact with the contact surface 3.1 of the printed circuit board 3 such that the second projection 1.2 is deformed in the area of ​​its free end 1.2.1 due to the higher strength of the printed circuit board 3. For good force transmission, the third component 3 rests on the third projection 2.3 of the second component 2, which is designed as a support.

[0028] See also Fig. Figure 2 shows an intermediate layer of the connected system during the joining of the three components 1, 2, and 3. During the joining process, i.e., the material-locking connection of the first and second components 1, 2 and the deformation of the second projection 1.2 of the first component 1 in contact with the surface 3.1 of the third component 3, the first component 1 is moved further along the joining axis 4 towards the second and third components 2, 3 due to the joining force F. The joining path s traveled in this way is only completed when the first component 1, with its fourth projection 1.4, rests against the second component 2. Due to the resulting increase in the joining force F, the laser welding process is terminated. The first component 1 is then welded to the second component 2 by means of the weld joint at the connecting surfaces 1.1 and 2.1.1. Due to the deformation of the second projection 1.2 is the third component 3 in the result by means of the first and the second component 1, 2 parallel to the common joining axis 4.

[0029] Based on the Fig. 3 and Fig. Section 4 below further explains the method according to the invention.

[0030] The above based on the Fig. 1 and Fig. The described material-bonded joining of the first and second components 1, 2 and the deformation of the second projection 1, 2 of the first component 1 by means of the common joining force F is controlled, namely as a function of a reference variable, i.e., a target variable. The reference variable is defined as a quotient of the joining path s and a joining time t. During the joining process, the joining force F is controlled as a manipulated variable as a function of the predetermined quotient, i.e., as a function of a specific value for the quotient, such that the quotient of joining path s and joining time t actually occurring during the joining process, as the controlled variable, remains essentially constant throughout the entire joining time t, i.e., essentially corresponds to the predetermined value of the quotient, i.e., the reference variable.

[0031] In the present embodiment, no quotient determined and fixed before the joining process is used; instead, the quotient is automatically determined as a reference variable in an initial phase of the joining time t and used as a reference variable for the subsequent remainder of the joining time t in the manner described above. See also Fig. Figure 3, in which a joining path-joining time diagram corresponding to the inventive method carried out using the exemplary embodiment of a connected system according to the invention is shown. In principle, however, it is also conceivable that the reference variable, namely the quotient, is determined and fixed beforehand in order to be used subsequently during the joining of the three components 1, 2 and 3.

[0032] Fig.Figure 4 shows a joining force-joining time diagram corresponding to the inventive method carried out using the exemplary embodiment. As can be seen from this diagram, the joining force F does not remain constant during the joining process, but is regulated as a function of the aforementioned quotient of joining path s and joining time t such that a quotient that is essentially constant throughout the entire joining process is obtained. The required increase in the joining force F during the joining process can be effected, for example, by means of an electric servomotor (not shown) in a manner known to those skilled in the art.

[0033] The inventive method and the inventive connected system make it possible in particular to connect relatively heavy third components, for example printed circuit boards equipped with heavy electrical components, to the first and second components and to fix them parallel to the joining axis by means of the first and second components.

[0034] The invention is not limited to the present embodiment. For example, other material-bonded connections, such as other welding processes or adhesive bonds, are also conceivable. The individual projections, connecting surfaces, and contact surfaces can also be freely selected within wide suitable limits according to the requirements of the individual case with regard to type, material, dimensions, number, and arrangement. For example, it is also possible for the second component to have at least one second projection, wherein the free end of the second projection of the second component is designed as a contact surface, and a third projection of the first component is arranged in the area of ​​the third component facing away from the second projection during deformation of the second component and acts as a support for the third component. Reference symbol list 1 First component, designed as a plastic housing half 1.1 Connection surface of the first component 1 1.2 Second projection of the first component, designed as a plastic dome 1.2.1 Contact surface of the plastic dome 1.2 1.4 Fourth projection of the first component 1, designed as a stop 2 Second component, designed as a plastic housing half 2.1 First projection of the second component 2 2.1.1 Connecting surface of the first projection 2.1 2.3 Third projection of the second component 2, designed as a support 3 Third component, designed as an electrical circuit board 3.1 Surface of the third component 3, designed as a contact surface 4 joining axes

Claims

[1] Method for joining three components (1, 2, 3) which has the following features: - Positioning the components (1, 2, 3) such that connecting surfaces (1.1, 2.1.1) of the first and second components (1, 2) and contact surfaces (1.2.1, 3.1) of the first or second component (1) and the third component (3) are opposite each other; - Material-bonded joining of the first and second components (1, 2) by means of the joining surfaces (1.1, 2.1.1) and deformation of the first or second component (1) in a region (1.2) of its at least one contact surface (1.2.1) in contact with the corresponding contact surface (3.1) of the third component (3), each by means of a common joining force F, wherein the first and second components (1, 2) as well as the first or second component (1) and the third component (3) are moved relative to each other along a common joining axis (4) and the third component (3) is fixed parallel to the joining axis (4) after the deformation of the first or second component (1) by means of the first and second components (1, 2), - characterized by that the components to be joined in the aforementioned manner do not allow the second component to pass through the third component. [2] Method according to claim 1, characterized by, that the joining force F is controlled or regulated as a function of a guide variable, wherein the guide variable is formed as a quotient of a joining path s and a joining time t. [3] Method according to claim 2, characterized by , that the joining force F is controlled or regulated in such a way that the quotient is essentially constant throughout the entire joining time t. [4] Method according to claim 2 or 3, characterized by , that the quotient is automatically determined in an initial phase of the joining time t and is used as a guide variable for the subsequent remainder of the joining time t. [5] Method according to any one of claims 1 to 4, characterized by that the material-joining process is carried out by welding, in particular laser welding. [6] A connected system comprising three interconnected components (1, 2, 3), wherein the first and second components (1, 2) have corresponding connecting surfaces (1.1, 2.1.1) for a material-bonded connection, and the first or second component (1) and the third component (3) have corresponding contact surfaces (1.2.1, 3.1), and wherein the connecting surfaces (1.1, 2.1.1) and the contact surfaces (1.2.1, 3.1) are designed and oriented towards each other such that the first and second components (1, 2) and the first or second component (1) and the third component (3) are movable relative to each other along a common joining axis (4), and the first and second components (1, 2) are material-bonded to each other by means of the connecting surfaces (1.1, 2.1.1) by means of a common joining force F, and the first or second component (1) is in a area (1.2) of which at least one contact surface (1.2.1) is deformed in contact with the corresponding contact surface (3.1) of the third component (3), wherein the third component (3) is fixed by means of the deformation between the first and the second component (1, 2) parallel to the joining axis (4), . characterized by that the components connected in the aforementioned manner do not allow the second component to pass through the third component. [7] A connected system according to claim 6, wherein the first component and / or the second component (2) has / has at least one first projection (2.1), wherein the free end (2.1.1) of the first projection (2.1) is formed as one of the connecting surfaces (2.1.1). [8] Connected system according to claim 6 or 7, characterized by, that the first component (1) or the second component has at least one second projection (1.2), wherein the free end (1.2.1) of the second projection (1.2) of the first or second component (1) is formed as a contact surface (1.2.1). [9] Connected system according to claim 6 or 7, characterized by, that the first component (1) has at least one second projection (1.2), wherein the free end (1.2.1) of the second projection (1.2) of the first component (1) is formed as a contact surface (1.2.1) and a third projection (2.3) of the second component (2) is arranged in the area of ​​the third component (3) facing away from the second projection (1.2) when deformed by the first component (1) and acts as a support for the third component (3), or that the second component has at least one second projection, wherein the free end of the second projection of the second component is formed as a contact surface and a third projection of the first component is arranged in the area of ​​the third component facing away from the second projection when deformed by the second component and acts as a support for the third component. [10] A connected system according to any one of claims 6 to 9, wherein the first component (1) and / or the second component has / has at least a fourth projection (1.4), wherein the free end of the fourth projection (1.4) is designed as a stop and limits a joining path s along the joining axis (4) when connecting the connected system.

Images