A caulking pin (15) is inserted into a mounting hole (21) provided in a metal case body (3), and the end portion of the caulking pin (15) is thermally caulked with a welding tip (24) to form a mold forming portion (17). A surplus absorption recess (31) is formed by enlarging the opening end of the mounting hole (21), and surplus resin is absorbed. The surplus absorption recess (31) is positioned inside a region of the mold forming portion (17). Therefore, the amount of molten surplus resin that protrudes outward from the welding tip (24) in the thermal caulking process is reduced.

There are provided a synthetic resin joined body and a method of manufacturing the same, with which it is possible to secure both of sealing performance of a fluid passage and joint strength between synthetic resin parts, even if an area of a portion to be welded is reduced. The synthetic resin joined body includes: a baffle plate; an oil passage forming member which comes in contact with the baffle plate; an oil passage which is formed between the baffle plate and the oil passage forming member and through which lubricant flows; a sealing portion which is formed by welding the baffle plate and the oil passage forming member to each other on an outer side of the oil passage to seal a periphery of the oil passage; and a joint portion for joining the baffle plate and the oil passage forming member to each other.

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 method includes a rotation locking step during which the rotation of the threaded hub about the central axis is blocked by heating a portion of the plug to soften, then by forcing the softened thermoplastic material to penetrate into, and then solidify in, a female cavity hollowed in the wall of the orifice to constitute a male member which fits into the female cavity. The female cavity forms, against the action of the male member, a guiding end stop preventing the male member, and therefore the hub, from rotating about the central axis to oppose any rotary screwing/unscrewing of the plug and maintaining a degree of freedom in axial translation along the central axis of the male member within the female cavity, so as not to impede a sliding of the hub and of its screw thread along the central axis against the wall.

A portable computing device is disclosed. The portable computing device includes a retention member that provides a force to a flexible circuit disposed in a top portion and a bottom portion of the portable computing device. The retention member limits movement of the flexible circuit when, for example, the flexible circuit receives a force in response to the top portion pivoting with respect to the bottom portion. The bottom portion of the portable computing devices includes a bottom case having multiple terraced regions. The terraced regions allow the bottom portion to receive additional internal components, such as one or more battery packs, a main logic board, and/or one or more speaker modules. The battery packs are secured to the terraced region via adhesive rings. Although the terraced regions require additional material removed from the bottom case, the internal components secured to the bottom case provide structural support.

A method of bonding a second object to a first object includes: providing the first object having a thermoplastic liquefiable material in a solid state; providing the second object having a surface portion that has a coupling structure with an undercut, so that the second object is capable of making a positive-fit connection with the first object; pressing the second object against the first object with a tool that is in physical contact with a coupling-in structure of the second object while mechanical vibrations are coupled into the tool; continuing to press and couple vibrations into the tool until a flow portion of the thermoplastic material of the first object is liquefied and flows into the coupling structures of the second object; and letting the thermoplastic material re-solidify to yield a positive-fit connection between the first and second objects by the re-solidified flow portion interpenetrating the coupling structures.

A system for assembling a plurality of components into an assembly is provided. The system includes an installation table, a first transfer robot, a second transfer robot, and an adhesive dispensing robot. The first transfer robot is configured to assemble some of the plurality of components into a first sub-assembly and transfer the first sub-assembly to the installation table. The second transfer robot is configured to assemble remaining ones of the plurality of components into a second sub-assembly, transfer the second sub-assembly to the installation table, and attach the second sub-assembly to the first sub-assembly. The adhesive dispensing robot is configured to apply an adhesive between the first sub-assembly and the second sub-assembly, after the second sub-assembly is attached to the first sub-assembly, to bond the second sub-assembly to the first sub-assembly.

A dual ultrasonic welder unit may be coupled to and carried by a mounting bracket including a base member extending in a an end of a robot arm and may include a first welder including a welding horn adjustable in a Z-axis direction by a first motor mounted within a mounting bar assembly of the first welder. The mounting bar assembly may be coupled to the base member and include a support for adjusting the location of the first welder in an X-axis direction by a second motor mounted to an extension member coupled to the base member and including a threaded member coupled to a follower member coupled to the mounting bar assembly. The dual ultrasonic welder may include a second ultrasonic welder fixedly coupled to the base member. Methods of controlling and operating the dual ultrasonic welding unit include steps of operating the robot and the first and second motors to position the first welder relative to the second welder unit for simultaneously performing ultrasonic welds on at multiple locations on a workpiece.

A module mount having at least one module that can be mounted on the module mount, wherein the module can be mounted on the module mount via at least one caulking element, such that the respective caulking element, which is composed of a thermoplastic, extends through a hole in a section of the respective module that can be mounted on the module mount made of a thermoplastic or thermoset, and is hot-caulked at an end projecting out of the hole, wherein at least one projection is formed on the section of the respective module that can be mounted on the module mount in the region of the respective hole of the section of the respective module that can be mounted on the module mount made of the thermoplastic or thermoset, which projection is engaged in a press fit with the hot-caulked end of the respective caulking element.

A method for forming a double-sided loop strap includes: receiving a continuous longitudinal strip of loop material including a strip-form base bearing a field of upstanding loops on a fastening side of the strip bounded by opposite longitudinal edges, folding each of the longitudinal edges away from the fastening side, such that the base overlaps itself, and securing the folded edges in place by permanently bonding together overlapped areas of the base to form the double-sided loop strap.