Two-part fastener molding with integrated assembly mechanism
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Solution Overview
Problem
The manufacturing process of pin and grommet fasteners is labor-intensive and costly due to the need for separate molds and assembly of two distinct components, which increases production time and risk of mismatched parts.
Innovation Solution
A system and method that uses a single fastener-molding housing with interconnected mold sections and an actuating assembly to form and assemble a pre-engaged fastener, where the pin and grommet are initially connected through a flash connection, allowing for efficient formation and ejection as a fully-formed unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate molds and assembly machinery are used to manufacture pin and grommet fasteners, then the fastener components can be produced and assembled, but the manufacturing process becomes labor-intensive and costly
Solution Approach 1:
The patent combines separate pin and grommet molding operations into a single integrated mold assembly. The mold includes a pin cavity and a grommet cavity that can form both components simultaneously in one manufacturing cycle, eliminating the need for separate molding operations and reducing assembly complexity
Solution Approach 2:
The integrated mold is divided into distinct functional sections: a pin molding section, a grommet molding section, and an assembly section. This segmentation allows each component to be formed in its dedicated cavity while maintaining overall integration, enabling simultaneous production and pre-assembly of multiple fasteners
2Adaptability or versatility
If separate pin and grommet components are manufactured and assembled, then replacement of worn parts is possible, but the risk of mismatched parts increases
Solution Approach 1:
The mold assembly performs preliminary alignment and positioning of pin and grommet components during the molding process. Features such as positioning pins, alignment ribs, and integrated guides ensure that components are pre-matched before final assembly, eliminating mismatched parts while maintaining the ability to replace individual components
3Ease of operation
If manual assembly of pin and grommet components is used, then flexibility in handling components is maintained, but production time increases
Solution Approach 1:
The mold assembly incorporates automated ejection mechanisms, stripper plates, and guide pins that automatically position and assemble components without manual intervention. The system self-regulates the assembly process through integrated mechanical features, maintaining operational simplicity while dramatically increasing production speed through automated simultaneous molding and assembly
Data Source
AI summary
A system for manufacturing a two-part fastener may include a fastener-molding housing and an actuating assembly. The fastener-molding housing may include a fastener mold having a first mold section connected to a second mold section through a flash connection mold section. The fastener mold is configured to receive fastener-forming material to form a pre-engaged fastener having a first fastener portion within the first mold section and a second fastener portion within the second mold section. The first fastener portion is temporarily secured to the second fastener portion through a flash connection portion formed within the flash connection mold section. The an actuating assembly includes a stripper plate, a connecting member, and at least one ejection member. The connecting member is configured to securely retain the first fastener portion. The stripper plate is configured to be moved relative to the connecting member in order to drive one of the first or second fastener portions into the other of the first or second fastener portions to form a fully-formed fastener. The ejection member is configured to eject the fully-formed fastener from the actuating assembly.