Method for welding a first component to a second component, welding device for welding a first component to a second component, and component comprising a first component and a second component

Abstract

The approach described here relates to a method for welding a first component (105) to a second component (110). The method comprises a step (205) of guiding at least one extension (120) arranged on a first side (115) of the first component (105) onto at least one weld rib (130) arranged on a second side (135) of the second component (110). The method further comprises a step (210) of joining the first component (105) to the second component (110) by means of a metallurgical bond, in particular by welding the extension (120) to the weld rib (130).

Description

[0001] The approach presented here relates to a method for welding a first component to a second component, a welding device for welding a first component to a second component and a component with a first component and a second component.

[0002] A form of welding can be used to permanently join several components together.

[0003] The approach presented here aims to provide an improved method for welding a first component to a second component, an improved welding device for welding a first component to a second component and an improved component with a first and a second component.

[0004] According to the approach presented here, this problem is solved by a method for welding a first component to a second component having the features of the main claims. Advantageous embodiments and further developments of the approach presented here are set out in the following subclaims.

[0005] A method for welding a first component to a second component comprises a step of guiding at least one extension arranged on a first side of the first component onto at least one welding rib arranged on a second side of the second component. The method also comprises a step of integrally connecting, in particular welding the extension to the welding rib, in order to weld the first component to the second component.

[0006] The first component and the second component can be formed from plastic only, for example, and can be used, for example, in a laundry care appliance such as a washing machine or a dryer.

[0007] A materially bonded connection can generally be understood as a connection in which the two connected components can normally no longer be separated or detached from one another. In particular, a materially bonded connection can be understood as welding. In concrete terms, this means that the extension can no longer be detached or separated from the welding rib after the connection. A welding rib can be understood as a projection protruding from the second side of the second component, which comes into contact with the extension and is connected to it in a materially bonded manner, i.e. in this case welded. An extension can be understood as a pin-shaped and / or rod-shaped, tapered projection that protrudes from the first side of the first component and forms a connection with the welding rib.

[0008] The approach presented here is based on the realization that any defects or irritations on the second component that could arise from welding the first component to the second component can be largely prevented by not welding the first component directly to the second component or not directly to the second side of the second component, but from the back of the second component and, if necessary, at a distance from the second side.

[0009] The approach presented here is advantageous in that welding two components together does not result in any defects or markings on a visible surface of the second component, especially on the side opposite the second component. Furthermore, the disclosed approach can avoid the sometimes very lengthy process optimization during welding, also known as welding, in order to produce surfaces that are largely acceptable to the user.

[0010] According to one embodiment, in the joining step, the extension can be connected to the welding rib in a welding plane located between the first component and the second component. In particular, the welding plane can be arranged closer to the first component than to the second component. Welding on the welding plane largely prevents stresses from being transferred to the visible surface during a cooling process after welding, which could lead to sink marks or indentations on the visible surface.

[0011] According to a further embodiment, in the joining step, a further extension of the first component can be connected to a further welding rib of the second component. The further extension can be arranged on the first side of the first component and guided onto the further welding rib, which can be arranged on the second side of the second component. This embodiment enables a further welded connection between the first component and the second component by connecting the further extension to the further welding rib, thereby further increasing the stability of the two components.

[0012] According to a further embodiment, at least a portion of the extension and / or at least a portion of the welding rib can be plasticized using ultrasound during the joining step. This allows the portion of the extension or the portion of the welding rib to transition from a solid state to a deformable or flowable state and become plastically deformable, thereby making the welding of the components simpler, more thorough, more targeted, and more efficient.

[0013] According to a further embodiment, the extension can be used as an energy director for directing energy to the welding rib during the joining step. This allows the components to be welded more thoroughly, more precisely, and more efficiently. Energy can thus be coupled in from a side of the first component opposite the first side, enabling a quick and efficient connection of the first and second components without causing aesthetic defects on a visible surface of the second component. If the energy is directed to the welding rib and not directly to the second side of the second component, stresses on the visible surface of the second component can also be largely prevented.

[0014] According to a further embodiment, a component having a welding rib designed as a hook-shaped projection protruding on the second side of the second component can be guided as the second component in the guiding step. The hook-shaped projection enables the welding plane on the hook-shaped projection to be generated, on which welding can take place, thereby avoiding error patterns or defects on the visible surface of the second component because, according to this embodiment, welding does not take place directly on the second side opposite the visible surface. A geometry of the hook-shaped projection, for example a rectangular geometry, can also sometimes eliminate long optimization times for a welding process because no defects are expected to become apparent on the visible surface as a result of welding.

[0015] According to a further embodiment, during the joining step, the extension can be connected to a leg of the welding rib facing away from the second side. If, during welding, welding energy is directed to the leg of the welding rib and not directly to the second side of the second component or the welding rib, stresses on the visible surface of the second component can be largely prevented.

[0016] In principle, the extension can be guided to the welding rib in any direction. For example, the extension can be guided close to the surface of the welding rib. According to a further embodiment, the extension can also be guided into a recess in the welding rib during the guiding step. This allows the welding of the components to be more thorough, targeted, and efficient. Directing the welding energy to the recess in the welding rib and not directly to the second side of the second component also largely prevents stress on the visible surface of the second component. At the same time, the connection is established over a larger surface area, making this connection more stable.

[0017] According to a further embodiment, a component in which the welding rib has a constriction can be guided as the second component in the guiding step. In this case, a cross-section of the welding rib can be smaller at the constriction than at a point outside the constriction. In particular, the constriction can be adjacent to the second side. The constriction and its smaller cross-section than at a point outside the constriction can generate a thermal resistance, which can largely and advantageously prevent excessive or unnecessarily strong penetration of the second component or the visible surface by heat generated during welding.

[0018] According to a further embodiment, a first component and / or a second component made of plastic can be guided in the guiding step. This enables a quick and cost-effective realization of the second and / or first component. For plastic components, it may be advisable or desirable that their surfaces be free of any visible dents, bumps, or waves caused by a welding process, so that these surfaces can be considered and approved as acceptable surfaces. Furthermore, it may be advisable to weld two plastic components together, for example, to be able to use them in a dryer or a washing machine.

[0019] The approach presented here further creates a control unit configured to execute, control, or implement the steps of a variant of a method presented here in corresponding units. This variant of the approach presented here in the form of a control unit also allows the task underlying the approach presented here to be solved quickly and efficiently.

[0020] The control unit can be designed to read in input signals and to determine and provide output signals using the input signals. An input signal can, for example, represent a sensor signal that can be read in via an input interface of the control unit. An output signal can represent a control signal or a data signal that can be provided at an output interface of the control unit. The control unit can be designed to determine the output signals using a processing rule implemented in hardware or software. For example, the control unit can comprise a logic circuit, an integrated circuit, or a software module and can, for example, be implemented as a discrete component or be comprised of a discrete component.

[0021] Also advantageous is a computer program product or computer program with program code that can be stored on a machine-readable carrier or storage medium such as a semiconductor memory, a hard disk memory, or an optical memory. If the program product or program is executed on a computer or a control unit, the program product or program can be used to carry out, implement, and / or control the steps of the method according to one of the embodiments described here.

[0022] Also presented is a welding device for welding a first component to a second component. The welding device can have a control unit and a welding head for welding the extension to the welding rib. Using the welding device, the above-described method for welding the first component to the second component can be carried out quickly and efficiently. The welding rib can be welded to the extension using the welding head. The individual steps of the method can be controlled or executed using the control unit and its units.

[0023] Furthermore, a machine-readable storage medium on which the computer program is stored is presented. This implementation of the approach presented here, in the form of a machine-readable storage medium, also allows the problem underlying the approach presented here to be solved quickly and efficiently.

[0024] Also presented is a component comprising a first component and a second component. The first component can have an extension on a first side, and the second component can have a welding rib on a second side. The extension can be integrally connected to the welding rib. The component comprising the two components can be used, for example, in a laundry care appliance. Such use of the component in the laundry care appliance can be made more cost-effective and efficient, in particular, by the component not exhibiting surface irritations.

[0025] Although the approach described is based on a household appliance, the approach described here can be used accordingly in connection with a commercial or professional device, for example a medical device, such as a cleaning or disinfection device, a small-scale sterilizer, a large-scale disinfector or a container washing system.

[0026] Examples of the approach presented here are shown purely schematically in the drawings and are described in more detail below. Fig. 1 a schematic representation of an embodiment of a component with a first and a second component; Fig. 2 shows an embodiment of a flow diagram of a method for welding a first component to a second component; and Fig. 3 a schematic representation of a control unit according to an embodiment.

[0027] The same or similar reference symbols are used in the following description for the same or similar elements, whereby a repeated explanation of the function of these elements is omitted for reasons of clarity.

[0028] Fig. 1 shows a schematic representation of an embodiment of a component 100 with a first component 105 and a second component 110. The first component 105, also referred to as component 1, is optionally made of plastic and has an extension 120 on a first side 115, which can also be referred to as an energy director, for example. The extension 120 is optionally connected in a welding plane 125, which is arranged, for example, closer to the first component 105 than to the second component 110, to a welding rib 130, which is arranged on a second side 135 of the second component 110. The welding rib 130 lies between the first component 105 and the second component 110, also referred to as component 2, which is optionally made of plastic. In a recess 140 of the welding rib 130 there is a part of the extension 120, which is optionally connected to the welding rib 130 in a materially bonded manner.Optionally, a leg 145 of the welding rib 130 facing away from the second side 135 is connected to the extension 120. The welding rib 130, also called an L-shaped rib, is optionally designed as a hook-shaped projection that protrudes on the second side 135 of the second component 110. For example only, the welding rib 130 has a constriction 150, at which a cross-section of the welding rib 130 is smaller than at a point outside the constriction 150. The constriction 150 borders, for example, the second side 135.

[0029] The first component 105 and the second component 110 are optionally welded together. For example, a welding head 155 of a welding device 160 is or was used to weld the extension 120 as an energy director to the welding rib 130 using a Fig. 3 of the welding device 160. Optionally, a further extension (not shown) on the first side 115 of the first component 105 is connected, in particular integrally connected, for example welded, to a further welding rib (not shown) on the second side 135 of the second component 110. On a visible surface 165 of the second component 110 opposite the second side 135, no dents, waviness, or other surface irritations caused by welding or subsequent cooling or cooling are expected to be visible. In other words, a surface, namely in this case the visible surface 165, should be as free as possible from dents, waviness, and other surface irritations for a user. In other words, the surface of the second component 110 should be as free as possible from visually perceptible or perceptible defects.According to an advantageous embodiment, the user can expect that no markings will appear on the surface of the second component 110 or the device 100.

[0030] Fig. 1 generally represents a particularly advantageous embodiment of the idea presented here, which is an alternative to the conventional variants, of using a welding rib 130 to improve the optically visible surfaces.

[0031] Fig. 2 shows an embodiment of a flow diagram of a method 200 for welding a first component to a second component. The method 200 comprises a step 205 of guiding at least one extension arranged on a first side of the first component onto at least one welding rib arranged on a second side of the second component. Optionally, in step 205 of guiding, the extension is guided into a recess in the welding rib. Optionally, in step 205 of guiding, a further extension of the first component is connected to a further welding rib of the second component. For example, in step 205 of guiding, the further extension is guided into a further recess in the further welding rib.

[0032] The method 200 further comprises a step 210 of materially bonding, in particular welding the extension to the welding rib, in order to weld the first component to the second component. In step 210 of bonding, the extension is optionally used as an energy director for directing energy to the welding rib. In step 210 of bonding, the extension is optionally connected to a leg of the welding rib that faces away from the second side. According to one embodiment, in step 210 of bonding, the extension is connected to the welding rib in a welding plane. In step 210 of bonding, optionally a part of the extension and a part of the welding rib are plasticized using ultrasound. In other words, an extension acting as an energy director can be plasticized by ultrasonic welding.Typically, one of the components contains at least one energy director, which plasticizes upon application of ultrasound, i.e., changes from a solid state to a deformable or flowable state and becomes plastically deformable. The energy director interacts with a joining partner, for example, with the material shown in . Fig. 1 shown recess of the welding rib, a connection.

[0033] The method 200 is exemplified using the Fig. 1 or a similar welding device. The welding device includes, for example, the welding device described in Fig. 3 or a similar control unit. According to one embodiment, the welding device further comprises a welding head for welding the extension to the welding rib.

[0034] Several components, for example, two components, should or can be welded together using method 200. According to one embodiment, the welding of the energy director does not take place directly on the back of the surface of the second component. For this purpose, for example, hut-shaped geometries of the welding rib can be formed. Such hut-shaped geometries can generate a new welding plane, so that, if possible, no stresses are transferred to the visible surface during the cooling process of the component.

[0035] In other words, by at least one embodiment of a geometry of the welding rib, in the best case scenario, long optimization times for a welding process or a welding device can be eliminated and a component surface can be immediately free of defects. In other words, the disclosed approach can sometimes avoid very long process optimizations during welding in order to be able to produce largely acceptable surfaces. By directly welding the first component to a surface of the second component, sink marks and impressions could occur on the surface. The sink marks often cannot be avoided even by a sacrificial foil. Because the Fig. 1, but rather on the welding rib(s), any defects on the surface, such as a plastic surface of the second component or the structural element, can be avoided.

[0036] Fig. 3 shows a schematic representation of a control unit 300 according to an embodiment. By means of the control unit 300, for example, the Fig. 2 for welding the first component to the second component. The control unit 300 comprises a guide unit 305 for carrying out or controlling a guiding of the at least one extension arranged on the first side of the first component on the at least one welding rib arranged on the second side of the second component. The control unit 300 further comprises a connection unit 310 for carrying out or controlling a material-to-material connection, in particular the welding of the extension to the welding rib, in order to weld the first component to the second component.

[0037] According to one embodiment, the approach presented here can also be referred to as welding geometry for plastic components or as an idea for welding two components and can be used, for example, in washing machines or dryers of different generations.

Claims

[1] Method (200) for welding a first component (105) to a second component (110), the method (200) comprising the following steps: - guiding (205) at least one extension (120) arranged on a first side (115) of the first component (105) onto at least one welding rib (130) arranged on a second side (135) of the second component (110); and - materially bonding (210), in particular welding the extension (120) to the welding rib (130), in order to weld the first component (105) to the second component (110). [2] Method (200) according to claim 1, wherein in the step (210) of connecting, the extension (120) is connected to the welding rib (130) in a welding plane (125) located between the first component (105) and the second component (110), in particular wherein the welding plane (125) is arranged closer to the first component (105) than to the second component (110). [3] Method (200) according to one of the preceding claims, wherein in the step (210) of connecting a further extension of the first component (105) is connected to a further welding rib of the second component (110). [4] Method (200) according to one of the preceding claims, wherein in the step (210) of joining at least a part of the extension (120) and / or at least a part of the welding rib (130) is plasticized using ultrasound. [5] Method (200) according to one of the preceding claims, wherein in the step (210) of joining, the extension (120) is used as an energy director for directing energy to the welding rib (130). [6] Method (200) according to one of the preceding claims, wherein in the step (205) of guiding, as the second component (110) a component is guided which has a welding rib (130) which is designed as a hook-shaped projection which protrudes on the second side (135) of the second component (110). [7] Method (200) according to claim 6, wherein in the step (210) of connecting, the extension (120) is connected to a leg (145) of the welding rib (130) which is remote from the second side (135). [8] Method (200) according to one of the preceding claims, wherein in the guiding step (205) the extension (120) is guided into a recess (140) of the welding rib (130). [9] Method (200) according to one of the preceding claims, wherein in the step (205) of guiding, a component is guided as the second component (110), in which the welding rib (130) has a constriction (150), wherein a cross section of the welding rib (130) at the constriction (150) is smaller than at a location outside the constriction (150), in particular wherein the constriction (150) adjoins the second side (135). [10] Method (200) according to one of the preceding claims, wherein in the step (205) of guiding a first component (105) and / or a second component (110) made of plastic is guided. [11] Control unit (300) which is designed to carry out and / or control the steps (205, 210) of the method (200) according to one of the preceding claims in corresponding units (305, 310). [12] Computer program product with program code for carrying out the method (200) according to one of claims 1 to 10, when the computer program product is executed on a control unit (300) according to claim 11. [13] Welding device (160) for welding a first component (105) to a second component (110), wherein the welding device (160) comprises a control unit (300) according to claim 11 and a welding head (155) for welding the extension (120) to the welding rib (130). [14] A machine-readable storage medium on which the computer program according to claim 12 is stored. [15] Component (100) with a first component (105) and a second component (110), wherein the first component (105) has an extension (120) on a first side (115), and wherein the second component (110) has a welding rib (130) on a second side (135), and wherein the extension (120) is integrally connected, in particular welded, to the welding rib (130).

Images