Ultrasonic bonding of discrete plastic parts to metal

Electricity: conductors and insulators – Boxes and housings – With electrical device

Reexamination Certificate

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C361S807000, C156S073100

Reexamination Certificate

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08049120

ABSTRACT:
Electronic devices and other apparatuses that include plastic parts ultrasonically bonded to metal parts are disclosed. A first component or part includes a metallic surface region having a surface roughness with one or more surface irregularities. A second component or part formed from a plastic material that can include an energy director is attached to the metallic surface region via an ultrasonic bond, such that a portion of the plastic material is melted or otherwise formed into the surface irregularities to attach the two components or parts together. The parts can be housings, internal components or other items. The surface irregularities can be formed as a result of a chemical etching process, a machining process, or a combination thereof, and can result in the creation of undercuts or cavities in the metallic surface region.

REFERENCES:
patent: 2009/0017242 (2009-01-01), Weber et al.
patent: 2009/0190290 (2009-07-01), Lynch et al.
patent: 2009/0260871 (2009-10-01), Weber
“Part Design for Ultrasonic Welding,” Branson, Technical Information PW-3, Applied Technologies Group, Feb. 2003.
U.S. Appl. No. 12/127,752, filed May 27, 2008.

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