Method and apparatus for vibration welding of thermoplastic components

A method for forming a vibratory welded connection between first and second members and a junction piece where said members and said junction piece are composed at least in part of thermoplastic resin material,

• said method comprising
• providing a vibratory head;
• providing a junction piece having a first portion for welding to said first and second members and a second portion extending from said first portion for mounting to a fixture connected to said vibratory head and for supporting said first portion from said fixture;
• mounting the second portion of said junction piece to a fixture connected to said vibratory head;
• mounting said first and second members in fixtures that are independent of said vibratory head;
• creating an engagement force between each of said first and second members and a respective opposite side of said first portion of said junction piece;
• maintaining said engagement forces while vibrating said junction piece by means of said vibratory head at a frequency of from 50 to 500 Hz to create friction generated heat to melt material on the ends of said members and on each respective opposite side of the first portion of said junction piece, such melted material upon cooling forming a weld between said junction piece and said members;
• where said engagement forces between said first and second members and said junction piece are applied separately from the operation of the vibratory head, wherein said first portion of said junction piece has a planar flange that extends at an angle with respect to each said member, where said second portion of said junction piece incorporates a removable tab that is an extension of said planar flange, and where said removable tab is held in said fixture that is connected to said vibratory head.