Dissatisfied with the conventional staking methods of Hot-Air, Heated Punch, and Ultrasonic, Extol set out to develop a more robust and consistent method of heating and forming a molded stud or boss.

Through our internal Innovation & Development group, the InfraStake process was created and patented, and in the last 8-years thousands of modules and hundreds of systems have been serving in production in various industries.

The advantages of this low impact, non-intrusive staking process are numerous. The consistency offered by InfraStake with its clean and efficient light energy have many of our customers specifying "across the board" this process on all staking applications.

The system pictured below is a standard 7-point InfraStake machine built to assemble an automotive interior trim component. The InfraView power supply/controller is mounted below the working surface - integrated into our standard, adjustable height ErgoStation table. The intuitive, color operator interface is ideally positioned for ease of use. The model shown has a customer specified guarding package with safety light-curtain and single opto-touch start switch package. 'Back lighting' is provided for operator convenience and positioned in such a manner as to prevent glare. A CNC machined fixture with part presence sensors is very typical on such a system.

When we break down the actual science of light energy and the manner it is applied in a standard InfraStake cycle, it is a relatively straight-forward process. Please review the schematic below:

The cross-section views depicted reveal the internal components of a typical InfraStake module. They are: the embedded lamp; the integrated staking punch; the reflector; and the concentrator. Not shown is the low-force, pneumatic cylinder which is mounted directly on top of the module. The staking punch detail is tied to this cylinder through a clever mechanism which allows for easy and quick disassembly for inspection.

1) Clamping & Heating

During this phase, the InfraStake module is presented to the sub-assembly on a main press/slide mechanism, this action positions the concentrator directly on the staking surface which provides optimum, integrated part clamping. The heating cycle is initiated through the illumination of the lamp. This 100watts (typical) 'technical application' grade lamp emits infrared (IR) light energy which is collimated and radially oriented in such a manner as to generate a focal point ideal for consistent, even heating of the subject boss or stud. The highly polished, gold-plated reflector and concentrator elements achieve this 'management' of the IR light energy as a function of the engineered geometries.

Heat time is a programmed function controlled by the user. In multiple head applications, each module is independently controlled - both heat and punch (hold) times. The InfraView power supply can drive up to (24) heads simultaneously and in addition to providing calibrated and conditioned power output for each module, the lamp current is a monitored function in order to assure process consistency and to provide potential lamp fault alert messages.

2) Staking & Cooling

At the end of the heating cycle the lamp is switched off, the low-impact air cylinder with integrated staking punch is activated which forms over the semi-molten stud. When we mention “low-impact”, it is important to note that the stud is heated so evenly that the force required is typically as low as 15 – 25lbs of true force. That means low stresses in the plastic and less potential damage to sensitive components in the proximity of the operation – as realized in PCB applications, for instance. The staking punch is not heated; it is positioned in the module outside of the IR focal point. Cooling or hold time therefore is very efficient as the formed stud re-solidifies under pressure. Stringy/sticky plastic adhering to the punch is also a non-issue with InfraStake due to the ‘cool’ punch surface.

3) Punch Retracts

At the end of the programmed hold or punch time, the internal staking punch mechanism retracts.

4) Head Retracts

At cycle completion the main press/slide mechanism retracts. The sub-assembly can be immediately handled.