HEAT STAKING MACHINES ARE BENEFICIAL WHEN JOINING TWO PARTS THAT CONSIST OF DIFFERENT MATERIAL WHICH CANNOT NORMALLY BE ULTRASONICALLY WELDED.

 

ADVANTAGES OF HEAT STAKING MACHINE

Thermal Presses heat the staking post/insert while applying pressure axially to permanently set the parts. Advantages of the thermal heat staking / inserting process include:
  • Reliable permanent inserts
  • No particulates or noise
  • Multiple level inserting/heat staking
  • Multiple size inserts
  • Better cosmetic appearance when heat staking and swaging High tolerance to mold release, colorants and other additives Ease of operation and assembly
  • Handles slippery thermoplastics
  • Easier maintenance in a low-tech environment
  • Cost effective
  • Short Cycle Times
  • Tight Assemblies
  • Excellent repeatability and process control Elimination of mechanical fasteners and adhesives

FEATURES HEAT STAKING MACHINE

  • 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
  • Can design the machine and fixture according to Customer’s requirements High-efficiency welding, low breakdown
  • Lift body electrically and change moulds conveniently and efficiently
  • HMI /MMI process controls provide easy set up and repeatability of control.
  • Quick disconnect heater elements
  • 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)

APPLICATIONS OF HEAT STAKING MACHINE

  • 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.

 

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
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
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
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 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
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
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