Mounting Noise-Producing Assemblies in Thermoplastic Elastomers
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Solution Overview
Problem
Mounting noise-producing structures in rubber-like thermoplastics is difficult, as existing methods are not effective for these materials.
Innovation Solution
A method involving the use of Styrene-Butadiene-Styrene (SBS) and Styrene-Ethylene-Butadiene-Styrene (SEBS) thermoplastic elastomers, where a noise-producing assembly is mounted into an aperture in a body portion made of SBS, which is conducive to gluing, and a second body portion made of SEBS is overmolded to engage the first, forming a durable bond without mechanical locking features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional mounting methods are used for noise producing structures, then mounting is easy in vinyl or natural rubber, but mounting becomes difficult in rubber-like thermoplastics
Solution Approach 1:
The patent applies local quality by creating a specific receiving portion with enhanced mounting features within the thermoplastic body. The receiving portion includes an aperture and mounting structures that are locally optimized for securing the noise producing assembly, while the rest of the body maintains its thermoplastic properties. This localized structural modification enables effective mounting in thermoplastics without compromising the overall material characteristics.
Solution Approach 2:
The patent segments the mounting function by separating the receiving portion (with mounting features) from the main body structure. The noise producing assembly is mounted in a dedicated receiving portion that includes an aperture and mounting structures, rather than attempting to mount directly in the bulk thermoplastic material. This segmentation allows specialized mounting mechanisms to be implemented in a localized area.
2Strength
If mechanical locking features are used for mounting, then mounting strength is improved, but device complexity increases
Solution Approach 1:
The patent merges the mounting function with the receiving portion structure itself. The receiving portion includes an aperture and mounting features that are integrated into the molded body, eliminating the need for separate mechanical locking components. The mounting structures are formed as part of the receiving portion geometry, combining structural support and mounting functions in a single integrated element.
Solution Approach 2:
The patent employs self-service mounting where the receiving portion's aperture and mounting structures are designed to secure the noise producing assembly through the molding process itself. The thermoplastic material and molded receiving portion structure provide the mounting mechanism without requiring additional external locking components or complex assembly steps.
Data Source
AI summary
A method of making a noise producing toy includes the steps of providing a noise producing assembly; providing or molding a first body portion having a first material and having an aperture, the first material having a material that is conducive mounting of the noise producing assembly into the aperture; mounting the first body portion on a mandrel of a mold core, the mold core for forming at least part of a body of the noise producing toy; molding a second body portion to engage the first body portion on a mold core to form at least part of the body, separating the mandrel and mold core and the at least part toy body; mounting the noise producing assembly into the aperture.