A method for producing a component with a surface that is suitable for plastic welding or adhesive bonding of two parts is provided. As a preparation step prior to joining, a filler sheet comprising a thermoplastic material or adhesive is arranged on a first surface of a first component and a structuring tool is arranged on the filler sheet. Mechanical force is applied to the structuring tool and heat is applied to the filler sheet such that the filler sheet is attached to the first surface of the first component and such that the structuring tool is partially embedded in the filler sheet. The structuring tool is subsequently removed from the filler sheet to produce a plurality of protrusions in the outer surface of the filler sheet. After surface structuring the first and second components are joined using any type of welding technique or joined using of adhesive bonding.

A method for optimizing a welding process to produce a weld joint having a predetermined strength includes measuring a plurality of melt layer thicknesses of weld joints for a plurality of sample assemblies formed by the welding process, measuring a plurality failure loads of weld joints for the plurality of sample assemblies, each of the measured plurality of failures loads being associated with one of the measured plurality of melt layer thicknesses, selecting a first failure load from the plurality of measured failure loads responsive to determining that the first failure load corresponds to a predetermined weld strength, and selecting a first melt layer thickness from the plurality of measured melt layer thicknesses that is associated with the selected first measured failure load.

Methods for ultrasonic welding of thermoplastic polymer workpieces and assemblies made therefrom are provided. The method may comprise disposing a first region of a first thermoplastic polymer workpiece and a second region of a second thermoplastic polymer workpiece between an ultrasonic horn and an anvil of an ultrasonic welding device. The first workpiece has a preformed deformation and at least one of the first and/or second workpieces has an adhesive precursor applied thereto. The ultrasonic horn or anvil seats within the preformed deformation. Ultrasonic energy is applied from the ultrasonic horn to create a weld nugget between the first and second workpieces. The assembly thus formed has a green strength sufficient to be further processed immediately. The methods provide a robust weld joint with controlled adhesive bondline thickness.

Methods for ultrasonic welding of thermoplastic polymer workpieces and assemblies made therefrom are provided. The method may comprise disposing a first region of a first thermoplastic polymer workpiece and a second region of a second thermoplastic polymer workpiece between an ultrasonic horn and an anvil of an ultrasonic welding device. The first workpiece has a preformed deformation and at least one of the first and/or second workpieces has an adhesive precursor applied thereto. The ultrasonic horn or anvil seats within the preformed deformation. Ultrasonic energy is applied from the ultrasonic horn to create a weld nugget between the first and second workpieces. The assembly thus formed has a green strength sufficient to be further processed immediately. The methods provide a robust weld joint with controlled adhesive bondline thickness.

A method for optimizing a welding process to produce a weld joint having a predetermined strength includes measuring a plurality of melt layer thicknesses of weld joints for a plurality of sample assemblies formed by the welding process, measuring a plurality failure loads of weld joints for the plurality of sample assemblies, each of the measured plurality of failures loads being associated with one of the measured plurality of melt layer thicknesses, selecting a first failure load from the plurality of measured failure loads responsive to determining that the first failure load corresponds to a predetermined weld strength, and selecting a first melt layer thickness from the plurality of measured melt layer thicknesses that is associated with the selected first measured failure load.

A method for optimizing a welding process to produce a weld joint having a predetermined strength includes measuring a plurality of melt layer thicknesses of weld joints for a plurality of sample assemblies formed by the welding process, measuring a plurality failure loads of weld joints for the plurality of sample assemblies, each of the measured plurality of failures loads being associated with one of the measured plurality of melt layer thicknesses, selecting a first failure load from the plurality of measured failure loads responsive to determining that the first failure load corresponds to a predetermined weld strength, and selecting a first melt layer thickness from the plurality of measured melt layer thicknesses that is associated with the selected first measured failure load.

Methods for ultrasonic welding of thermoplastic polymer workpieces and assemblies made therefrom are provided. The method may comprise disposing a first region of a first thermoplastic polymer workpiece and a second region of a second thermoplastic polymer workpiece between an ultrasonic horn and an anvil of an ultrasonic welding device. The first workpiece has a preformed deformation and at least one of the first and/or second workpieces has an adhesive precursor applied thereto. The ultrasonic horn or anvil seats within the preformed deformation. Ultrasonic energy is applied from the ultrasonic horn to create a weld nugget between the first and second workpieces. The assembly thus formed has a green strength sufficient to be further processed immediately. The methods provide a robust weld joint with controlled adhesive bondline thickness.

A method for optimizing a welding process to produce a weld joint having a predetermined strength includes measuring a plurality of melt layer thicknesses of weld joints for a plurality of sample assemblies formed by the welding process, measuring a plurality failure loads of weld joints for the plurality of sample assemblies, each of the measured plurality of failures loads being associated with one of the measured plurality of melt layer thicknesses, selecting a first failure load from the plurality of measured failure loads responsive to determining that the first failure load corresponds to a predetermined weld strength, and selecting a first melt layer thickness from the plurality of measured melt layer thicknesses that is associated with the selected first measured failure load.

A resin member contains a thermoplastic resin and is bonded to another resin member by ultrasonic welding. The resin member includes: a melting start portion to which contact pressure is applied during the ultrasonic welding; a groove unit that is formed around a periphery of the melting start portion; and at least one wall that is formed so as to cross a direction from the melting start portion toward an outside and partitions the groove unit.