Sonotrode, Method for Welding a Ball, and Component Connection

Abstract

A method is provided for welding a ball to another component. The method includes: providing a sonotrode which has a trough-shaped recess, in particular a spherical cap-shaped recess; pressing the ball against the other component by the sonotrode, the ball protruding into the trough-shaped recess; and vibrating the ball by the sonotrode such that material of the ball and/or material of the other component melts, and the ball is welded to the other component.

Claims

1. A sonotrode, comprising: a vibration generating device, wherein the sonotrode is provided in order to weld a ball to another component, the sonotrode has a trough-shaped recess, which is provided in order to be placed against the ball in an areally contacting manner and in order to transmit ultrasound vibrations generated by the vibration generating device to the ball.

2. The sonotrode according to claim 1, wherein the vibration generating device is configured to generate translational vibrations.

3. The sonotrode according to claim 2, wherein the vibration generating device is configured to generate rotational vibrations.

4. The sonotrode according to claim 1, wherein the vibration generating device is configured to generate rotational vibrations.

5. The sonotrode according to claim 1, wherein the sonotrode comprises a negative pressure duct opening into the trough-shaped recess.

6. The sonotrode according to claim 4, wherein a suction device is provided by which a negative pressure for sucking on the ball is generated in the negative pressure duct.

7. The sonotrode according to claim 5, wherein the suction device is arranged in or on the sonotrode.

8. The sonotrode according to claim 1, wherein the trough-shaped recess has a curvature radius that is equal to a radius of the ball.

9. The sonotrode according to claim 7, wherein the curvature radius is approximately equal to 3.175 mm.

10. The sonotrode according to claim 1, wherein the trough-shaped recess has a spherical-cap shape.

11. A method for welding a ball to another component, the method comprising the acts of: providing a sonotrode, which comprises a trough-shaped recess; pressing the ball against the other component by the sonotrode, wherein the ball projects into the trough-shaped recess; and inducing vibrations in the ball by the sonotrode in such a manner that material of the ball and/or material of the other component melts and the ball is welded to the other component.

12. The method according to claim 11, wherein translational vibrations are induced in the ball by the sonotrode.

13. The method according to claim 12, wherein rotational vibrations are induced in the ball by the sonotrode.

14. The method according to claim 11, wherein rotational vibrations are induced in the ball by the sonotrode.

15. The method according to claim 11, wherein the other component, in a place in which the ball is pressed on, is substantially or exactly flat, so that prior to welding there is a punctiform contact between the ball and the place in which the ball is pressed on.

16. The method according to claim 11, wherein the ball is sucked onto or into the trough-shaped recess by a suction device, and in the sucked-on or sucked-in state is pressed against the other component by the sonotrode.

17. The method according to claim 16, wherein the ball, through the sucking-on, is removed from a ball reservoir.

18. The method according to claim 11, wherein the ball is made of plastic material.

19. The method according to claim 18, wherein the other component is made from plastic material.

20. A component connection, comprising a ball and another component, wherein the ball is welded to the other component via ultrasound welding.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0031] FIG. 1 is a schematic diagram illustrating the basic principle of the welding of a ball to another component by way of an ultrasound sonotrode.

[0032] FIGS. 2A and 2B show that because of the ball geometry the distance between the sound introduction point and the contact point is identical even upon an inclined position (FIG. 2B) of the sonotrode.

DETAILED DESCRIPTION OF THE DRAWINGS

[0033] FIG. 1 shows a flat component 1, which can for example be a fiber-reinforced plastic component (e.g. a fiber-reinforced body part of a vehicle). A ball 2, which can likewise consist of a plastic material, is to be welded onto the surface la of the component 1 by use of an ultrasound sonotrode 3.

[0034] The ultrasound sonotrode, which is only shown in highly schematic form here, has, on its lower side or on its lower face end 3a, a trough-shaped or spherical cap-shaped recess 3b. In the exemplary embodiment shown in FIG. 1, the radius of the spherical cap-shaped recess 3b exactly or substantially corresponds to the radius of the ball 2.

[0035] A negative pressure duct 4a, which is fluidically connected via a negative pressure duct 4b branching off from the same to a negative pressure generating device 5 arranged on the sonotrode 3 (which is only shown in a highly schematic form here), opens into the spherical cap-shaped recess 3b. By means of the negative pressure generating device 5, a suction can be generated in the trough-shaped recess 3b via the negative pressure ducts 4a, 4b, which is indicated by an arrow 6. Through the suction, the ball 2 is sucked against the sonotrode 3 in such a manner that an upper region of the ball 2 projects into the trough-shaped recess.

[0036] In the sucked-on state, the ball 2 can be guided to the component 1 or to the surface la of the component 1 and pressed against the component 1 by moving the sonotrode, for example by use of an industrial robot. By means of a vibration generating device which is integrated in the sonotrode 3 (not shown in more detail here), translational vibrations (indicated by a double arrow 7) and/or rotational vibrations (indicated by a double arrow 8) can be induced in the ball 2. Because of this, a very high energy density is created in the contact region (substantially point contact) of the ball 2 with the surface la of the component 1, which locally limited leads to the melting of the material of the ball and/or of the material of the component 1 and thus to a welding of the ball to the component 1.

[0037] For the sake of completeness, reference is made to FIG. 2A and 2B. As is evident from a comparison of FIG. 2A and FIG. 2B, the distance d between the sound introduction point and the contact point is always identical in magnitude because of the entirely symmetrical geometry of the ball 2 even upon an inclined position of the sonotrode.

[0038] The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and equivalents thereof.