Patent ID: 7534316

Claim:
A method for assembling a reel, the method comprising: selecting a tube formed of a first thermoplastic in an extrusion process, the tube characterized by a first melt index and having a first end and a second end; selecting a first flange formed of a second thermoplastic characterized by a second melt index and having a containment region sized to receive the first end of the tube; maintaining continuous, relative, rotary motion of the tube and flange with respect to one another; imposing axial relative motion of the tube and flange with respect to one another simultaneously with the continuous, relative, rotary motion; capturing a liquified portion of the first thermoplastic proximate the first end of the tube; heating further the liquified portion by substantially continuous, relative, rotary motion; containing the liquified portion substantially surrounding a first portion of the wall penetrating the flange, the liquified portion of the first thermoplastic being maintained within a solid portion of the containment region maintaining pressure in the liquified portion contained therein; heating, by the liquified portion of the flange in contact therewith, a melting portion of the first end of the tube into a fluid state; mixing the liquified portion of the flange with the melting portion of the tube; ceasing the relative rotary motion and axial motion; welding the tube and flange by solidifying the mixture of the liquified portion and the melting portion in a chemical bond.