A method of joining polymer components includes additively manufacturing first and second mating features on first and second polymer components such that a mechanical lock is created through undercut geometric features of an adhesive material when the polymer components are joined. Adhesive is added between the mating components to strengthen the joint.

A ultrasonic welding method of joining dissimilar-material workpieces, such as sheet materials, and the joined components formed thereby. The method includes applying ultrasonic energy to a thermoplastic piece to fill a hole of a dissimilar piece to form a weld point that is made up with polymer from the thermoplastic piece. In general, the geometry of the thermoplastic piece is not altered during the process. The dissimilar piece generally has a higher melting temperate and can be metal, thermoset polymers, or other thermoplastic material. The welded pieces can be arranged in a lap, laminate, or double lap configuration. In some embodiments, the hole of the dissimilar sheet material includes undercut features that improve the mechanical interlock between the dissimilar pieces. In some embodiments, the weld point has a mushroom cap to improve mechanical interlock.

A system and method are provided for implementing relatively low temperature joining processes, including displacement/vibration welding techniques and/or heat staking techniques, in a process of building up laminate layers to form and/or manufacture three-dimensional objects, parts and components in additive material (AM) manufacturing systems. A multi-stage 3D object forming scheme is described involving steps of laminate cutting (with lasers or other cutting devices); laminate transport between processing stations (including using one or more of conveyors, robotic pick and place devices and the like); laminate stacking, clamping and adhering through comparatively low temperature welding or other mechanical joining (including displacement/vibration welding or heat staking); and mechanical surface finishing (via CNC machining or other comparable process).

A method and an apparatus for ultrasonic staking a first part having a fastening portion to a second part having an opening corresponding to the fastening portion. The method comprises aligning the fastening portion of the first part with the corresponding opening in the second part, inserting a head of the fastening portion through the corresponding opening, and causing a horn of an ultrasonic staking stack to contact the head, apply ultrasonic energy oscillating at a frequency between 45 kHz and 75 kHz, and move along an axis of the fastening portion as the head melts to form a stake. The stake can include a melt-form that joins the first part and the second part to each other, and the fastening portion can have a geometry or a size disposed to flapping.

The present disclosure can provide for an ultrasonic welding method for a pair of workpieces. The method can include first pressing an ultrasonic welding stack against a first workpiece in the pair so that the first workpiece comes into contact with a second workpiece in the pair. The method can then provide for initiating a weld phase by outputting energy from the ultrasonic welding stack to the first workpiece. The method can provide for monitoring, with at least one sensor, a sensed parameter. The sensed parameter can be, for example, weld force and/or weld force rate of change. The method can provide for determining whether the sensed parameter has reached a predetermined level. Based on determining that the sensed parameter has reached the predetermined level, the method can provide for ending the weld phase.

A fastening structure comprises a first plate, a second plate, and a sheet member. The first plate has a first passageway with a first diameter. The second plate has a protrusion with a second diameter smaller than the first diameter. The sheet member is disposed on the first plate such that a second passageway of the sheet member communicates with the first passageway of the first plate and the first plate is interposed between the sheet member and the second plate. A portion of the protrusion extends through the first passageway and the second passageway. The first plate is fastened to the second plate by thermal deformation of the portion of the protrusion extending through the first passageway and the second passageway or by overmolding to the portion of the protrusion extending through the first passageway and the second passageway.

A vehicle headlamp includes a reflector unit including plural reflectors connected to each other, and base portions to which the reflectors are connected respectively, plural light-source units disposed on the base portions for the respective reflectors, plural heat radiation members disposed on the respective light-source units. The base portions are provided with plural heat radiation member fixing ribs extending to a side opposite to the reflectors. The heat radiation members are formed with plural heat radiation member fixing holes having a diameter larger than that of the heat radiation member fixing ribs. Each of the heat radiation member fixing ribs is inserted through the respective one of the heat radiation member fixing holes and thermally crimped such that a gap is formed between an inner peripheral surface of the heat radiation member fixing hole and an outer peripheral surface of the heat radiation member fixing rib.

A system and method are provided for implementing relatively low temperature joining processes, including displacement/vibration welding techniques and/or heat staking techniques, in a process of building up laminate layers to form and/or manufacture three-dimensional objects, parts and components in additive material (AM) manufacturing systems. A multi-stage 3D object forming scheme is described involving steps of laminate cutting (with lasers or other cutting devices); laminate transport between processing stations (including using one or more of conveyors, robotic pick and place devices and the like); laminate stacking, clamping and adhering through comparatively low temperature welding or other mechanical joining (including displacement/vibration welding or heat staking); and mechanical surface finishing (via CNC machining or other comparable process).

A system and method for processing and detecting nucleic acids from a set of biological samples, comprising: a capture plate and a capture plate module configured to facilitate binding of nucleic acids within the set of biological samples to magnetic beads; a molecular diagnostic module configured to receive nucleic acids bound to magnetic beads, isolate nucleic acids, and analyze nucleic acids, comprising a cartridge receiving module, a heating/cooling subsystem and a magnet configured to facilitate isolation of nucleic acids, a valve actuation subsystem configured to control fluid flow through a microfluidic cartridge for processing nucleic acids, and an optical subsystem for analysis of nucleic acids; a fluid handling system configured to deliver samples and reagents to components of the system to facilitate molecular diagnostic protocols; and an assay strip configured to combine nucleic acid samples with molecular diagnostic reagents for analysis of nucleic acids.

A method of riveting using a plastically deformable plastic rivet is provided. The method includes positioning the plastic rivet in front of the rivet on a component, of a motor vehicle, and deforming the rivet by a riveting die by applying a riveting force, such that a rivet holds the component wherein the rivet is with a rivet dynamometer and the riveting force is measured and a rivet is set with a predetermined breaking point.