Breakaway plug ultrasonically bored from first thermoplastic part & ultrasonically bonded to surface of second thermoplastic part

The method of providing an assembly of thermoplastic parts separable responsive to the application of a predetermined force upon a breakaway plug comprising:

• assembling a first thermoplastic upper part in an overlapping relation upon a second thermoplastic lower part;
• providing a horn rendered resonant as a half wavelength resonator at an ultrasonic frequency and having at its free frontal end a bore, the depth of which is substantially equal to the thickness of the material of said first part at the location where said horn is intended to engage said first part;
• providing forced engagement between said horn and said first part at said location and causing said horn to penetrate into said first part, causing thermoplastic material to be cut from said first part and enter into said bore for forming a solid plug, whereby leaving a cavity in said first part;
• continuing motion of said horn toward the underlying second part until the end surface of said plug confronting said second part is in contact with said second part for welding said plug to the surface of said second part;
• maintaining for a brief time interval said horn at the position at which there is contact between said end surface of said plug and said second part;
• ceasing the horn to be resonant for causing softened and flowed thermoplastic material, produced at the interface between said plug and said second part responsive to the dissipation of vibratory energy, to rigidify;
• withdrawing said horn from said second part and said first part whereby to leave said plug free-standing but welded to said second part with the wall of the aperture produced in said first part responsive to cutting said plug surrounding a portion of said plug, and
• whereby, responsive to a predetermined breakaway force applied between said wall of said aperture and said plug, said plug breaks away from its attachment to said second part, thereby rendering said first part and said second part separable.