Method and insert for connecting components to plastic members

A plastic article formed of joined pieces, comprising:

• a molded body molded of a plastic material and having at least one recess-defining wall therein, of a predetermined size and shape;
• a hollow projecting boss of plastic material having an interconnecting portion thereon sized and shaped to engage the recess-defining wall of the molded body;
• meltable plastic portions on boss and on the molded body integrally mixed at the recess-defining wall and the interconnecting portion of the wall to integrally bond the boss to the plastic body;
• the plastic body being formed of a first plastic material;
• the plastic boss being formed of a second different plastic material;
• and
• a projection on the boss abutting the body and limiting the insertion depth into the recess, and the plastic of the projection being integrally intermixed with the plastic of the body.

A method of forming a non-cylindrical plastic body with at least one projecting plastic boss projecting outwardly from the plastic body and having a plurality of plastic protrusions on the boss, said method comprising the steps of:

• providing a non-cylindrical plastic body with a wall defining a recess therein sized to receive a connecting portion of the plastic boss;
• providing a plastic boss with a connecting portion sized to contact the recess-defining wall in the plastic body;
• inserting the portion of the plastic boss into the recess and into contact with one another;
• bringing the plastic protrusions on the boss and the recess-defining wall into a flowable state at their interface;
• intermixing the flowable plastic materials of the body and the boss;
• solidifying the intermixed plastic materials to integrally bond the plastic of the boss to the plastic of the body;
• providing a body of a first plastic material;
• and
• providing a boss of a second and different plastic material.

A method of forming a non-cylindrical plastic body with at least one projecting plastic boss projecting outwardly from the plastic body and having a plurality of plastic protrusions on the boss, said method comprising the steps of:

• providing a non-cylindrical plastic body with a wall defining a recess therein sized to receive a connecting portion of the plastic boss;
• providing a plastic boss with a connecting portion sized to contact the recess-defining wall in the plastic body;
• inserting the portion of the plastic boss into the recess and into contact with one another;
• bringing the plastic protrusions on the boss and the recess-defining wall into a flowable state at their interface;
• intermixing the flowable plastic materials of the body and the boss;
• solidifying the intermixed plastic materials to integrally bond the plastic of the boss to the plastic of the body;
• and
• threading a metal screw into an opening in the boss.

A method of forming a non-cylindrical plastic body with at least one projecting plastic boss projecting outwardly from the plastic body and having a plurality of plastic protrusions on the boss, said method comprising the steps of:

• providing a non-cylindrical plastic body with a wall defining a recess therein sized to receive a connecting portion of the plastic boss;
• providing a plastic boss with a connecting portion sized to contact the recess-defining wall in the plastic body;
• inserting the portion of the plastic boss into the recess and into contact with one another;
• bringing the plastic protrusions on the boss and the recess-defining wall into a flowable state at their interface;
• intermixing the flowable plastic materials of the body and the boss;
• solidifying the intermixed plastic materials to integrally bond the plastic of the boss to the plastic of the body;
• providing a body in the form of a flat plastic sheet with a plurality of recesses therein;
• and
• inserting a plurality of bosses into the recesses and integrally bonding each of the bosses to the flat sheet.

A method of forming a non-cylindrical plastic body with at least one projecting plastic boss projecting outwardly from the plastic body and having a plurality of plastic protrusions on the boss, said method comprising the steps of:

• providing a non-cylindrical plastic body with a wall defining a recess therein sized to receive a connecting portion of the plastic boss;
• providing a plastic boss with a connecting portion sized to contact the recess-defining wall in the plastic body;
• inserting the portion of the plastic boss into the recess and into contact with one another;
• bringing the plastic protrusions on the boss and the recess-defining wall into a flowable state at their interface;
• intermixing the flowable plastic materials of the body and the boss;
• solidifying the intermixed plastic materials to integrally bond the plastic of the boss to the plastic of the body;
• and
• positioning an ultrasonic welding horn adjacent the protrusions and recess-defining wall and using the ultrasonic welding horn to bring their respective plastic materials into a flowable state to intermix.

A method of forming a non-cylindrical plastic body with at least one projecting plastic boss projecting outwardly from the plastic body and having a plurality of plastic protrusions on the boss, said method comprising the steps of:

• providing a non-cylindrical plastic body with a wall defining a recess therein sized to receive a connecting portion of the plastic boss;
• providing a plastic boss with a connecting portion sized to contact the recess-defining wall in the plastic body;
• inserting the portion of the plastic boss into the recess and into contact with one another;
• bringing the plastic protrusions on the boss and the recess-defining wall into a flowable state at their interface;
• intermixing the flowable plastic materials of the body and the boss;
• solidifying the intermixed plastic materials to integrally bond the plastic of the boss to the plastic of the body;
• and
• coating at least one of the bosses or recess-defining wall with a bonding agent that liquifies the plastic materials of the boss and the body to intermix them.

A method of forming a non-cylindrical plastic body with at least one projecting plastic boss projecting outwardly from the plastic body and having a plurality of plastic protrusions on the boss, said method comprising the steps of:

• providing a non-cylindrical plastic body with a wall defining a recess therein sized to receive a connecting portion of the plastic boss;
• providing a plastic boss with a connecting portion sized to contact the recess-defining wall in the plastic body;
• inserting the portion of the plastic boss into the recess and into contact with one another;
• bringing the plastic protrusions on the boss and the recess-defining wall into a flowable state at their interface;
• intermixing the flowable plastic materials of the body and the boss;
• solidifying the intermixed plastic materials to integrally bond the plastic of the boss to the plastic of the body;
• molding a first plastic body with a mold and with recess-defining walls being at first locations and attaching bosses thereto at these locations;
• and
• molding another one of these first plastic bodies in the same mold but with recess-defining walls at second locations;
• and
• attaching bosses to the another plastic body at these second locations.

A method for fastening a plastic component to a plastic base having a wall thereon, comprising the steps of:

• providing a plastic component having an integral interlocking portion having a surface with a plurality of projections thereon being formed integrally with the interlocking portion, providing the projections in a circular array with the projections being spaced circumferentially from each other at defined spaces;
• force fitting the plastic interlocking portion of the component against the wall of the base;
• bringing the plastics of the engaged plastic interlocking component and the base to a flowable state at their interface and causing flow of the respective plastics together;
• rapidly melting the projections with ultrasonic energy to lose their shape and identity and flowing the plastic from the melted projections circumferentially into the defined spaces, and melting the plastic of the wall of the plastic base with ultrasonic energy opposite the defined spaces and melding together the plastics of the former projections and the wall;
• and
• bringing the flowed and melded plastics of the components's interlocking portions and base back to their ambient, solid conditions.