An apparatus to join two panels together includes a chamber, a horn positioned within the chamber, the horn moving reciprocally within the chamber, and a set of heating elements positioned about the horn to heat the horn. One of the panels has a post molded to it, the post extending through the other panel, and after the horn is heated an end of the horn is placed on top of the post and is ultrasonically vibrated to form a head of the post to join the two panels together.

A mechanical assembly for securing a first sheet to a second sheet includes a first projection having a first sidewall and a first top wall. The first sidewall extends from the first top wall at a first acute angle. The first sidewall includes a first top end and a first bottom end. A first discontinuity is defined in the first sidewall between the first top end and the first bottom end. A first base wall extends from the first bottom end. The first base wall extends generally parallel to the first top wall.

The present invention is to provide a vehicular interior member in which three components can be strongly joined to each other and the weight can be reduced. A vehicular interior member is formed so that first and second components respectively made of thermoplastic resin, and a middle component arranged between the first component and the second component are joined to each other. The first component has a boss projecting to the second component side. The middle component has a through hole through which the boss is inserted. The second component has a through hole through which the boss is inserted, and a fitting portion projecting to the middle component side, the fitting portion being fitted to an edge portion of the through hole. The boss and the second component are welded 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 of anchoring a lightweight building element having a first building layer and an interlining layer distally of the first building layer, and possibly a second building layer distally of the interlining layer. For anchoring, the the distal end of a connector element is inserted into a mounting hole in the lightweight building element, and also a sleeve including a thermoplastic material is inserted into the mounting hole, the sleeve enclosing the connector element. Then, a distally facing liquefaction face of the sleeve is caused to be in contact with a proximally facing support face of the connector element. Energy impinges to liquefy at least a flow portion of the thermoplastic material of the sleeve, and the liquefaction face is pressed against the support face to cause at least a fraction of the flow portion to flow radially outward. After the flow portion has re-solidified, it anchors the connector element in the receiving object.

A mechanical assembly for securing a first sheet to a second sheet includes a first projection having a first sidewall and a first top wall. The first sidewall extends from the first top wall at a first acute angle. The first sidewall includes a first top end and a first bottom end. A first discontinuity is defined in the first sidewall between the first top end and the first bottom end. A first base wall extends from the first bottom end. The first base wall extends generally parallel to the first top wall.

The invention relates to a method for producing a component bond (70, 140) comprising: a fastening structure (60, 160) that has at least one component layer (60; 160a, 160b); and a thermoplastic connecting element (10, 110) having a head (12) and a shank (14), in which method the connecting element (10, 110) is driven into the fastening structure (60, 160) under pressure whilst rotating, such that the shank (14) penetrates the fastening structure (60, 160). The connecting element (10, 110), after penetrating the fastening structure (60, 160), is converted by friction into a softened, free-flowing state in a die (44, 144) which is placed against the fastening structure (60, 160) in the opposite direction to the driving direction, resulting in a thicker section (22, 22) that extends beyond the radial extent of some sections of the shank (14). The fastening structure (60, 160) is thus interlockingly held between the head (12) and the thicker section (22, 122).

A rivet connection has a hollow rivet composed of plastics material and connects a first component to a second component. The first component has a first surface and the second component has a second and third surface. The first surface and the second surface bear on one another. The second component has a first opening between the second and the third surface. The hollow rivet has a tubular component having a lateral wall, a cavity, a first end and a second end. Part of the tubular component is disposed in the first opening of the second component. The second end of the tubular component protrudes beyond the second component. The lateral wall of the tubular component adjacent the first opening of the second component is heated and compressed and configures an outwardly bulging region. Part of the outwardly bulging region contacts the third surface of the second component.

An apparatus to join two panels together includes a chamber, a horn positioned within the chamber, the horn moving reciprocally within the chamber, and a set of heating elements positioned about the horn to heat the horn. One of the panels has a post molded to it, the post extending through the other panel, and after the horn is heated an end of the horn is placed on top of the post and is ultrasonically vibrated to form a head of the post to join the two panels together.

A method for joining a device to an object with the aid of a combination of ultrasonic vibration energy and induction heating, wherein the device includes a portion of a thermoplastic polymer and a susceptor additive wherein this portion is at least partly liquefied or plasticized through the ultrasonic vibration energy in combination with the induction heating and wherein the joining includes establishing a connection between the device and the object which connection is at least one of a positive fit connection, a weld, a press fit connection, and an adhesive connection. The induction heating is applied for rendering the device portion suitable for absorption of ultrasonic vibration energy than other device portions by raising its temperature above the glass transition temperature of the polymer. The ultrasonic vibration energy is used for liquefying or at least plasticizing the thermoplastic polymer of the named device portion.