Heat Staking

»Information

T.A. Systems' Hot Air/ Cold Stake process simultaneously upsets any number of bosses on various planes, levels and angles; thereby, staking two or more components together. It is one of the most cost effective methods for mechanically attaching thermoplastic components, and is equally affective for fastening dissimilar materials such as metals and circuit boards to a thermoplastic substrates.

»About Hot Air/Cold Staking

The process reforms molded studs and or bosses producing a mechanical bond. Each stud or boss is softened by blowing a controlled flow of heated (hot) air across the boss, or surface to be joined. Once the stud is softened a cold tool than reforms the stud/boss under low pressure to form the desired head shape. As the stud/boss is being reformed the heat is extracted from the plastic ensuring solid, stress, damage and rattle free component assembly with no tool sticking.

»Process Benefits

  • Cost effective
  • Short Cycle Times
  • Tight Assemblies
  • Excellent repeatability and process control
  • Elimination of mechanical fasteners and adhesives

»Machine 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 - lexan or expanded metal
  • Allen Bradley process controls provide easy set up and repeatability of control.
  • Standard Hot Air guns with pulsating ambient (shop) air to avoid burnout and stringing
  • 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)

»Sequence of Operations

  1. An operator loads the components to be staked into a Urethane or contoured aluminum nest
  2. The cycle is activated
  3. The part is then raised up to the upper platen, containing the Hot Air guns softening the material.
  4. The part is staked
  5. The part is lowered for removal