Integral joining

• US 7,160,405 B2
• Filed: 11/19/2004
• Issued: 01/09/2007
• Est. Priority Date: 06/18/1999
• Status: Expired due to Term

• Current Assignee: Woodwelding AG
• Original Assignee: Woodwelding AG
• Inventors: Torriani, Laurent, Mock, Elmar, Aeschlimann, Marcel
• Primary Examiner(s): SELLS, JAMES D
• Application Number:
  US10/993,028
• Publication Number:
  US 20050126680A1
• Time in Patent Office: 781 Days
• Field of Search: 156/73.1, 156/73.5, 156/73.6, 156/293, 156/297, 156/298, 156/580, 156/580.1, 156/580.2, 264/442, 264/443, 264/445, 264/68
• US Class Current: 156/73.1
• CPC Class Codes: B23K 35/0288 Welding studs
• CPC Class Codes: B29C 2793/0045 Perforating
• CPC Class Codes: B29C 65/08 using ultrasonic vibrations non-plastics element to plastics elements B29C65/645
• CPC Class Codes: B29C 65/562 using extra joining elements, i.e. which are not integral with the parts to be joined using plastic snap elements B29C65/58; using plastic rivets B29C65/601
• CPC Class Codes: B29C 65/564 hidden in the joint, e.g. dowels or Z-pins B29C65/603 takes precedence
• CPC Class Codes: B29C 65/606 the rivets being integral with one of the parts to be joined, i.e. staking
• CPC Class Codes: B29C 65/645 using friction or ultrasonic vibrations
• CPC Class Codes: B29C 66/112 Single lapped joints
• CPC Class Codes: B29C 66/114 Single butt joints
• CPC Class Codes: B29C 66/30221 said melt initiators being point-like
• CPC Class Codes: B29C 66/30223 said melt initiators being rib-like
• CPC Class Codes: B29C 66/30326 in the form of porosity
• CPC Class Codes: B29C 66/472 said single elements being substantially flat
• CPC Class Codes: B29C 66/474 said single elements being substantially non-flat
• CPC Class Codes: B29C 66/52631 with a right angle, e.g. for making L-shaped pieces
• CPC Class Codes: B29C 66/5268 characterised by their solid cross sections being non-circular, e.g. being elliptical, square or rectangular
• CPC Class Codes: B29C 66/723 being multi-layered B29C66/7292, B29C66/72941 take precedence
• CPC Class Codes: B29C 66/727 being porous, e.g. foam
• CPC Class Codes: B29C 66/7392 characterised by the material of at least one of the parts being a thermoplastic
• CPC Class Codes: B29C 66/7463 Concrete
• CPC Class Codes: B29C 66/7487 : Wood
• CPC Class Codes: B29C 66/8322 : Joining or pressing tools reciprocating along one axis
• CPC Class Codes: B29C 66/9511 : by measuring their vibration frequency
• CPC Class Codes: B29C 66/9512 : by controlling their vibration frequency
• CPC Class Codes: B29C 66/9515 : by measuring their vibration amplitude
• CPC Class Codes: B29C 66/9516 : by controlling their vibration amplitude
• CPC Class Codes: F16B 5/08 : by means of welds or the like welding B23K
• CPC Class Codes: Y10S 411/908 : Resinous material
• CPC Class Codes: Y10T 156/109 : Embedding of laminae within face of additional laminae
• CPC Class Codes: Y10T 403/477 : Fusion bond, e.g., weld, etc.

Abstract

A method for joining bodies by melting down a joining element. The joining element acts on a surface of one of the bodies and penetrates the surface as a result of a directed force. Once in a penetrated condition, a mechanical excitation is generated such that during further penetration of the joining element into the one body, the advance is maintained through the directed force and the melting down is maintained through the mechanical excitation. Molten or melted material is hydraulically displaced into the bodies.

Claims

1. A method of anchoring a joining element in a first body comprising a porous material, wherein the joining element has first and second end portions, said first end portion comprising a thermoplastic material, said method comprising the steps of:

positioning the first end portion of the joining element on a surface of the first body;

applying a force to the second end portion of the joining element such that the first end portion of the joining element breaks through the surface of the first body and penetrates into the porous material; and

once the first end portion of the body reaches a predetermined depth in the porous material of the first body or once the force reaches a predetermined level, mechanically exciting the joining element, while still applying the force to the second end portion, whereby the mechanical excitation and the applied force to the joining element liquefies the thermoplastic material of the first end portion and hydraulically displaces the liquefied thermoplastic material into the porous material of the first body, thereby anchoring the joining element in the first body.

2. The method according to claim 1, wherein the joining element is mechanically excited by applying an ultrasound vibration to the second end of the joining element.

3. The method according to claim 1, wherein mechanical excitation is achieved by rotating the joining element around an axis extending between the first and second end portions.

4. The method according to claim 3, wherein the joining element is rotated while the force is applied to the second end portion of the joining element and assists in breaking through the surface of the first body.

5. The method according to claim 4, further comprising the step of disposing a second body over the first body, said second body having an opening extending therethrough, and wherein the step of positioning the first end portion of the joining element is performed by inserting the first end portion of the joining element through the opening in the second body and into contact with the surface of the first body.

6. The method according to claim 5, further comprising the steps of:

positioning a layer of material between the first and second bodies, said material layer being liquefiable by the mechanical excitation; and

,

liquefying the material layer and thereby sealing the first and second bodies to one another.

7. The method according to claim 1, comprising the further steps of:

securing the second end of the joining element in a holder; and

,

applying said force and said mechanical excitation to said joining element second end through said holder.

8. The method according to claim 7, wherein the joining element is mechanically excited by applying an ultrasound vibration to the second end of the joining element.

9. The method according to claim 7, wherein mechanical excitation is achieved by rotating the joining element around an axis extending between the first and second end portions.

10. The method according to claim 9, wherein the joining element is rotated while the force is applied to the second end portion of the joining element and assists in breaking through the surface of the first body.

11. The method according to claim 10, further comprising the step of disposing a second body over the first body, said second body having an opening extending therethrough, and wherein the step of positioning the first end portion of the joining element is performed by inserting the first end portion of the joining element through the opening in the second body and into contact with the surface of the first body.

12. The method according to claim 11, further comprising the steps of:

positioning a layer of material between the first and second bodies, said material layer being liquefiable by the mechanical excitation; and

,

liquefying the material layer and thereby sealing the first and second bodies to one another.

13. The method according to claim 1, wherein the first end portion of the joining element is pointed.

14. The method according to claim 1, wherein the first body includes a covering layer and the joining element breaks through the covering layer when force is applied to the second end portion of the joining element.