Heatstaking machines are beneficial when joining two parts that consist of different material which cannot normally be ultrasonically welded.
Features
- Although each machine is custom built for its specific application, the following information details typical machine features.
- Rugged, tubular steel frame construction using the highest quality components
- Safety guarding
- HMI /MMI process controls provide easy set up and repeatability of control.
- Quick disconnect heater elements
- Palm buttons and emergency stop
- Controlled air flow
- Heater Burnout Alarms (optional)
- Closed loop systems for process monitoring (optional)
- Light Screens for protection (optional)
- Touch Screens (optional)
- Digital timer for weld time and post-cool
- Auto & Manual Setup mode head down for probe alignment with component
- Prewired and preprogrammed for optional slide kits, post cool, and fixture clamping.
- LVDT for slide conformation (optional)
Benefits
- Cost effective
- Short Cycle Times
- Tight Assemblies
- Excellent repeatability and process control
- Elimination of mechanical fasteners and adhesives
Applications
- Thermal press applications include heat staking, inserting, embossing, date coding and degating.
- Automotive industry for door panels, map pockets, light-pipe staking, consoles, arm rests and switch clusters.
- Medical applications include blood-processing equipment, chemical pumps, fittings, flow meters, IV drug delivery and surgical instruments.
- Consumer Product applications include personal computers, portable telephones, laser printers, copy machines, video games, speakers and appliance components.
- Industrial applications include conveyor systems, gears, pulleys, couplings, and motor housings. Thermal presses are also used in Toy Manufacturing and the Sporting Goods industry
The goal of a heat stake is to reform a plastic stud or protrusion over a mating component to lock it into place.
Hollow Stake
- Works well with Large diameter studs
- Produces a large strong head
- Does not have to melt a large amount of material (less time, less force)
- Avoids sink marks on the opposite side of molded component
- Enables parts to be re-assembled with self-tapping screws should repair or dis-assembly be necessary
Rosette or Flared
- Recommended for large diameter posts
- Flares out material giving 360 degrees of even holding strength
- Stakes / moves more volume easily
- Slightly less staking forces required
- Slightly less cycle time as opposed to a dome stake on large studs
- Alignment to our staking heads is critical
- Requires very accurate positioning so that center point of tip contacts center of stud
- Not generally recommended for use on heated platens (best on probes) because of thermal expansion
- Not generally recommended on small diameter studs
- Aesthetically looks like a rivet
Knurled Stake
- Alignment is not an important consideration from an application standpoint
- Ideally suited for high volume production
- Three styles available: fine knurl, medium knurl, coarse knurl
- Generally the pitch/texture of the knurl is related to diameter of stud to be staked
- Can knurl a large tool and hit many stakes without alignment worries
- Good use on heated platens where thermal expansion is generally a problem
- Also works well when mating component has a countersink
- Greatly reduces cycle time
Rosette Low
- Recommended for large diameter posts
- Flares out material giving 360 degrees of even holding strength
- Stakes / moves more volume easily
- Less staking forces required
- Slightly less cycle time as opposed to a dome stake on large studs
- Alignment is critical
- Requires very accurate positioning so that center point of tip contacts center of stud
- Not generally recommended for use on heated platens (best on probes) because of thermal expansion
- Not generally recommended on small diameter studs
Flush Stake
- Used for applications requiring a flush surface
- Requires that mating component has sufficient thickness for a countersink, counterbore, or a combination of the two
- Volume of the boss is crucial to fill the countersink properly
Dome/Conical High Profile
- Produces a tight stake
- Recommended for crystalline material with sharp melting points
- Highly defined melting temperatures, (post cooling a must)
- Good for glass filled materials, or materials with abrasive fillers
- Good for materials that degrade easily (post cooling)
- Dome stakes come in two profiles: High and Low
- Works well into counter bored holes
