Heat staking process with increased retention force

Abstract

A heat staking method and apparatus is provided for use in deforming a heat-stake so that it becomes mechanically coupled to an encapsulate. The deformed portion of the heat-stake contacts a retention component that provides additional composition strength and fastening surface to the encapsulate.

1 - 20 . (canceled) 
     
     
         21 . An automotive vehicle comprising:
 a first automotive part;   a second automotive part;   a first thermoplastic heat stake comprising a base portion attached to the first automotive part and a shaft portion having an end that extends from the base portion;   a first thermoplastic encapsulate attached to the second automotive part and having an opening;   a first thermoplastic retention component having a passage that is over-molded or co-injection molded onto the first thermoplastic encapsulate adjacent the opening of the first thermoplastic encapsulate; and,   wherein a mechanical coupling of the first automotive part to the second automotive part is formed by: (1) inserting the shaft portion of the first thermoplastic heat stake through the opening in the first thermoplastic encapsulate and through the passage in the first thermoplastic retention component; and, (2) heating the end of the shaft portion of the first thermoplastic heat stake to deform the heated end of the inserted shaft portion of the first thermoplastic heat stake to at least partially overlap the first thermoplastic retention component.   
     
     
         22 . The automotive vehicle of  claim 21  further comprising:
 a second thermoplastic heat stake comprising a base portion attached to the first automotive part and a shaft portion having an end that extends from the base portion; 
 a second thermoplastic encapsulate attached to the second automotive part and having an opening; 
 a second thermoplastic retention component having a passage that is over-molded or co-injection molded onto the second thermoplastic encapsulate adjacent the opening of the second thermoplastic encapsulate; and, 
 wherein a mechanical coupling of the first automotive part to the second automotive part is also formed by: (1) inserting the shaft portion of the second thermoplastic heat stake through the opening in the second thermoplastic encapsulate and through the passage in the second thermoplastic retention component; and, (2) heating the end of the shaft portion of the second thermoplastic heat stake to deform the heated end of the inserted shaft portion of the second thermoplastic heat stake to at least partially overlap the second thermoplastic retention component. 
 
     
     
         23 . The automotive vehicle of  claim 21  wherein:
 the opening in the first thermoplastic encapsulate has a perimeter; and, 
 the first retention component substantially covers the perimeter of the opening in the first thermoplastic encapsulate after the mechanical coupling is formed. 
 
     
     
         24 . The automotive vehicle of  claim 21  wherein the deformed end of the of the shaft portion of the first thermoplastic heat stake does not contact the first thermoplastic encapsulate after the mechanical coupling is formed. 
     
     
         25 . The automotive vehicle of  claim 21  wherein when the first thermoplastic retention component is over-molded or co-injection molded onto the first thermoplastic encapsulate, the passage in the first thermoplastic retention component is substantially co-linear with the opening in the first thermoplastic encapsulate. 
     
     
         26 . The automotive vehicle of  claim 21  wherein the first thermoplastic retention component is over-molded onto the first thermoplastic encapsulate. 
     
     
         27 . The automotive vehicle of  claim 21  wherein the first thermoplastic retention component is co-injection molded onto the first thermoplastic encapsulate. 
     
     
         28 . The automotive vehicle of  claim 21  wherein:
 the first thermoplastic retention component is formed of a first composition; 
 the first thermoplastic encapsulate is formed of a second composition; and, 
 the first composition is harder than the second composition. 
 
     
     
         29 . The automotive vehicle of  claim 21  wherein:
 the first thermoplastic heat stake is formed of a first composition; 
 the first thermoplastic encapsulate is formed of a second composition; and, 
 the first composition is harder than the second composition. 
 
     
     
         30 . The automotive vehicle of  claim 21  wherein:
 the first thermoplastic heat stake is formed of a first composition; 
 the first thermoplastic encapsulate is formed of a second composition; and, 
 the first composition has a higher melting point than the second composition. 
 
     
     
         31 . The automotive vehicle of  claim 21  wherein:
 the opening in the first thermoplastic encapsulate has a first diameter; 
 the passage in the first thermoplastic retention component has a second diameter; and, 
 the second diameter is less than the first diameter. 
 
     
     
         32 . An automotive manufacturing assembly comprising:
 a shaping device;   a first automotive part;   a second automotive part;   a first thermoplastic heat stake comprising a base portion attached to the first automotive part and a shaft portion having an end that extends from the base portion;   a first thermoplastic encapsulate attached to the second automotive part and having an opening;   a first thermoplastic retention component having a passage that is over-molded or co-injection molded onto the first thermoplastic encapsulate adjacent the opening of the first thermoplastic encapsulate; and,   wherein a mechanical coupling of the first automotive part to the second automotive part is formed by: (1) inserting the shaft portion of the first thermoplastic heat stake through the opening in the first thermoplastic encapsulate and through the passage in the first thermoplastic retention component; and, (2) using the shaping device to heat the end of the shaft portion of the first thermoplastic heat stake to deform the heated end of the inserted shaft portion of the first thermoplastic heat stake to at least partially overlap the first thermoplastic retention component.   
     
     
         33 . The automotive manufacturing assembly of  claim 32  further comprising:
 a second thermoplastic heat stake comprising a base portion attached to the first automotive part and a shaft portion having an end that extends from the base portion; 
 a second thermoplastic encapsulate attached to the second automotive part and having an opening; 
 a second thermoplastic retention component having a passage that is over-molded or co-injection molded onto the second thermoplastic encapsulate adjacent the opening of the second thermoplastic encapsulate; and, 
 wherein a mechanical coupling of the first automotive part to the second automotive part is also formed by: (1) inserting the shaft portion of the second thermoplastic heat stake through the opening in the second thermoplastic encapsulate and through the passage in the second thermoplastic retention component; and, (2) using the shaping device to heat the end of the shaft portion of the second thermoplastic heat stake to deform the heated end of the inserted shaft portion of the second thermoplastic heat stake to at least partially overlap the second thermoplastic retention component. 
 
     
     
         34 . The automotive manufacturing assembly of  claim 32  wherein the first thermoplastic retention component is over-molded onto the first thermoplastic encapsulate. 
     
     
         35 . The automotive manufacturing assembly of  claim 32  wherein the first thermoplastic retention component is co-injection molded onto the first thermoplastic encapsulate. 
     
     
         36 . An automotive assembly comprising:
 first and second automotive parts;   a first thermoplastic heat stake comprising abuse portion attached to the first automotive part and a shaft portion having an end that extends from the base portion;   a first thermoplastic encapsulate attached to the second automotive part and having an opening;   a first thermoplastic retention component having a passage that is over-molded or co-injection molded onto the first thermoplastic encapsulate adjacent the opening of the first thermoplastic encapsulate; and,   wherein a mechanical coupling of the first automotive part to the second automotive part is formed by: (1) inserting the shaft portion of the first thermoplastic heat stake through the opening in the first thermoplastic encapsulate and through the passage in the first thermoplastic retention component; and, (2) heating the end of the shaft portion of the first thermoplastic heat stake to deform the heated end of the inserted shaft portion of the first thermoplastic heat stake to at least partially overlap the first thermoplastic retention component.   
     
     
         37 . The automotive assembly of  claim 36  further comprising:
 a second thermoplastic heat stake comprising abuse portion attached to the first automotive part and a shaft portion having an end that extends from the base portion; 
 a second thermoplastic encapsulate attached to the second automotive part and having an opening; 
 a second thermoplastic retention component having a passage that is over-molded or co-injection molded onto the second thermoplastic encapsulate adjacent the opening of the second thermoplastic encapsulate; and, 
 wherein a mechanical coupling of the first automotive part to the second automotive part is also formed by: (1) inserting the shaft portion of the second thermoplastic heat stake through the opening in the second thermoplastic encapsulate and through the passage in the second thermoplastic retention component; and, (2) heating the end of the shaft portion of the second thermoplastic heat stake to deform the heated end of the inserted shaft portion of the second thermoplastic heat stake to at least partially overlap the second thermoplastic retention component. 
 
     
     
         38 . The automotive assembly of  claim 36  wherein the first thermoplastic retention component is over-molded onto the first thermoplastic encapsulate. 
     
     
         39 . The automotive assembly of  claim 36  wherein the first thermoplastic retention component is co-injection molded onto the first thermoplastic encapsulate. 
     
     
         40 . The automotive assembly of  claim 36  wherein:
 the first thermoplastic heat stake is formed of a first composition; 
 the first thermoplastic encapsulate is formed of a second composition; and, 
 the first composition is harder than the second composition or the first composition has a higher melting point than the second composition.