A respiratory apparatus may employ ultrasonic welds. The ultrasonic welding may be used to join a variety of headgear, mask and accessory components. This process may enhance comfort, fit and/or performance of the joined components and/or overall mask assembly. A component may be a single layer component such as a textile or fabric, or a composite or multiple layer component such as fabric and foam composites, or outer fabric layers and inner spacer fabrics. Further, a component may be a strap, some other headgear component, a mask component, an accessory component or the like.

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.

An apparatus for joining a first film portion and a second film portion together along a seal line. The apparatus includes a horn and an anvil. The anvil is positionable in close proximity to the horn. Either the horn or the anvil has a face with a width dimension and a circumference and is rotatable about a rotation axis. The face has a raised profile, and a height of the raised profile has a dimension corresponding to 50% to 150% of a thickness of the first film portion or the second film portion. The face is positioned such that the raised profile extends along the circumference such that continuous running contact is provided between the raised profile and the other of the one of the horn or the anvil when rotated about the rotation axis, to form the seal line without any external structure to control a distance between the horn and the anvil.

This manufacturing method for a resin molded body includes: a step in which an intermediate molded body made of a resin composition is prepared, the intermediate molded body having a rough surface with a maximum peak height (Rp) of 10-5000 μm measured according to JIS B 0601 or a maximum valley depth (Rv) of 10-5000 μm measured according to JIS B 0601; and a step in which a thin film-like molded body is fused to the rough surface of the intermediate molded body by irradiation with a laser, the thin film-like molded body being made of a resin composition containing reinforcing fibers arranged in one direction.

An electrolyte conductor (1) has a nonwoven fabric (2), onto which a plastic film (3) is laminated. A process is provided for the manufacture of the electrolyte conductor (1). An electrochemical gas sensor (10) is provided with such an electrolyte conductor (1). A gas-measuring device is provided with such a gas sensor (10).

A foam assembly system is provided. The system is configured to heat a surface of foam. After the heating of the foam, an adhesive is applied, typically a high solids adhesive. The foam is then bonded to another foam surface. It has been found that the pre-heating of the foam before adhesive application greatly enhances the bond strength between the foam and the second foam surface to which it is adhered.

A method of assembling a first part made from a metal and a second part includes providing a first part comprising an assembly surface, and a second part comprising at least one through orifice. At least part of the second part is arranged on the assembly surface such that the orifice extends across from the assembly surface. A metal connecting part is positioned on the orifice to cover the orifice across from the assembly surface. The connecting part and/or the assembly surface are projected on one another to obtain high-speed plating and welding between the connecting part and the surface part.

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.

A pair of thermoplastic resin members are placed on an anvil. A pressing force of a tool horn vibrating ultrasonically in a direction not perpendicular to but along upper surfaces of the pair of thermoplastic resin members is applied to the upper surfaces. The application of the pressing force of the tool horn vibrating ultrasonically allows melting of a vicinity of the upper surfaces of the pair of thermoplastic resin members. A welded structure part is formed on an unwelded structure part, thereby welding the pair of thermoplastic resin members as an overlap structure including the welded structure part arranged on the unwelded structure part. The distance and positional relationship between the pair of thermoplastic resin members after the welding are unchanged before and after the welding. The surfaces, placed on the anvil, of the thermoplastic resin members are neither burned nor discolored.

A method for manufacturing a metal-clad laminate sheet including forming a laminate sheet having the thermoplastic liquid crystal polymer film and the metal foil bonded together; and providing the laminate sheet with a heat treatment which satisfies conditions (1) and (2) below: (1) a heat treatment temperature ranges between 1° C. inclusive and 50° C. exclusive higher than a melting point of the thermoplastic liquid crystal polymer film. (2) a time for the heat treatment ranges from one second to 10 minutes.