Clinching During Injection Molding Process
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Solution Overview
Problem
The existing manufacturing process for parts made from injection molded plastic and multiple metal components is costly due to the need for separate stages of clinching metal pieces and injecting molten plastic around them.
Innovation Solution
A process that integrates clinching and injection molding by using a mold with a punch and die mechanism to form connections between metal components while injecting molten material around them, reducing the number of manufacturing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate stages of clinching and injection molding are used, then metal components can be connected and plastic can be formed around them, but manufacturing cost increases and production efficiency decreases
Solution Approach 1:
The patent combines the clinching process and injection molding process into a single integrated operation. The punch portion with its small and large diameter portions simultaneously performs the clinching action on metal components while the mold cavity receives molten plastic material, eliminating the need for separate manufacturing stages and reducing overall production cost and time.
Solution Approach 2:
The punch portion is designed with multi-functionality, serving both as a clinching tool to join metal components and as part of the molding system that shapes the plastic. The small diameter portion creates the clinch connection while the large diameter portion interacts with the mold cavity to form the plastic part, making a single component perform multiple functions.
2Reliability
If two separate manufacturing stages are used for clinching and injection molding, then each process can be optimized independently, but the overall manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The invention merges two previously separate manufacturing stages into one integrated process. The punch portion with its specialized small and large diameter portions performs both clinching and injection molding functions simultaneously, reducing process complexity while maintaining the ability to optimize each function through careful design of the punch and mold interfaces.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This integrated process reduces manufacturing costs by eliminating the need for a separate clinching stage, improving efficiency and streamlining the production of parts with both plastic and metal components.
Implementation Method 1
a force is applied to the large diameter portion such that an area of the first metal component and an area of the second metal component are displaced into the die to form the at least one connection point
Implementation Method 2
Molten material, such as a thermoplastic, is injected into the mold around the first metal component and the second metal component, forming the desired part using the first metal component, the second metal component, and the hardened molten material
Data Source
AI summary
The integration of two separate manufacturing processes involving joining two pieces of metal using a clinching or Tog-L-Loc™ type of connection, while also injecting a molten material around the two pieces of metal to create the desired part. A process for creating the desired part made of both plastic and metal includes the steps of providing a first metal component, a second metal component, inserting the first metal component into a mold, and inserting the second metal component into the mold. At least one connection point is used for connecting the first metal component to the second metal component while the metal components are located in the mold. Molten material, such as a thermoplastic, is injected into the mold around the first metal component and the second metal component, forming the desired part using the first metal component, the second metal component, and the hardened molten material.