A method of altering a portion of a substrate may include providing a first device and a second device with a nip therebetween. The second device may comprise a stationary or rotating source of vibration energy. When conveyed through the nip, the substrate may be exposed to the vibration energy and the portion thereof may be altered. Thermal energy may be applied to the portion of the substrate upstream of the nip to raise a temperature of the portion of the substrate to a temperature below a melting temperature thereof. A substrate spreader may contact the substrate upstream of the nip to mitigate fold over or wrinkles in the substrate. When the first device is a rotating anvil and the second device comprises a rotating source of vibration energy, the surface velocities thereof may be variable and may be the same or different.

Embodiments herein include a system for joining components. The system can include a rotating base platform, a plurality of receptacles mounted to the base platform, and a rotating sonotrode platform. A plurality of sonotrodes are mounted to the sonotrode platform. Each sonotrode can correspond to a receptacle. Each sonotrode can move in a reciprocating motion between a release position distant from a corresponding receptacle and a compressing position proximal to the corresponding receptacle. The compressing position occurs at a first angular position of the sonotrode platform. Each sonotrode is energized at the compressing position.

Apparatus are provided for ultrasonic welding of a workpiece of one or more components. The apparatus includes a horn configured to contact the workpiece and to transmit energy to the workpiece. The horn includes a shank and a tip disposed at an end of the shank facing the workpiece. The tip has a face that has a tip radius forming a curved surface at the face. A knurl is formed on the face across the curved surface.

An add-on part (10) for connecting to a component (30). The add-on part (10) has a longitudinal axis (A) and a welding section (11) to be welded to the component (30) by torsional ultrasonic welding. The welding section (11) has a contact surface (12) for contact with a torsion sonotrode (70) and a welding surface (13) for connecting to the component (30). The welding section (11) is delimited, at least in some sections, by an inner vibration-decoupling zone (14). The inner vibration-decoupling zone (14) extends, at least in some sections, at an inclination to or parallel to the longitudinal axis (A). The method comprises a) bringing the welding surface (13) in contact with a welding region (31), b) applying a force to the contact surface (12) such that the welding surface (13) is pressed against the welding region (31), and c) introducing a torsional ultrasonic vibration into the welding section.

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 device comprising a first fixing element, a further fixing element, and a folded planar composite is disclosed. The first fixing element comprises a first fixing surface and the further fixing element comprises a further fixing surface. The folded planar composite is at least partially fixed between the first fixing surface and the further fixing surface. The folded planar composite comprises a first composite region and a further composite region.

Methods of bonding a first object to a second object, including the steps of: providing the second object having a protrusion; providing the first object having a thermoplastic material; positioning the first object relative to the second object such that an assembly of the first and the second object is formed; applying a relative force between the second and first objects and applying mechanical vibration to the assembly of the first and the second object until at least a flow portion of the thermoplastic material becomes flowable and flows around the protrusion; and causing the thermoplastic material to re-solidify. The first object may be a connecting element including a feedthrough, wherein the second object has a corresponding opening. The protrusion may be deformed such that the protrusion has an undercut relative to an axis along which the first and second objects are pressed against each other.

A method of bonding a first object to a second object, including the steps of: providing a profile body having a first profile body portion; providing the first object, wherein the first object has thermoplastic material; providing the second object, wherein the profile body is separate from and attachable to the second object or wherein the second object includes the profile body; embedding the profile body in the first object such that the first profile body portion is within the thermoplastic material of the first object. Embedding the profile body in the first object is caused by mechanical energy impinging on the first object and/or on the second object while the first object and the second object are pressed against each other.

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.

An ultrasonic welding method for joining a first thermoplastic part and a second thermoplastic part without causing visible read-through on an exposed surface of the second part. The method includes arranging the first part on an inner surface of the second part. The inner surface is opposite the exposed surface. The first part has an interface portion contacting the inner surface. The method includes causing a horn of an ultrasonic welding stack to be pressed against the first part by applying ultrasonic energy oscillating at a frequency in a range of 45-70 kHz through the horn, to thereby join the first part and the second part together. The horn has at least one protruding distal portion configured to penetrate through the first part as the ultrasonic energy is imparted through the horn. The distal portion has a length longer than a thickness of the first part. A collapse distance of a weld formed at the interface portion is less than the thickness of the first part, to avoid read-through effects on the exposed surface of the second part.