Adhesive Fastener with Non-Uniform Hook Density for Foam Molding
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Solution Overview
Problem
Conventional adhesive fasteners for foam molding face issues with inadequate adhesive force between foam material and the fastener, leading to loose connections and increased costs due to the need for retaining walls in molds, which complicate the manufacturing process and result in defective items.
Innovation Solution
The adhesive fastener features a strip with first hooks arranged at a specific density in the center and second hooks at a higher density on the periphery, forming blocking zones that prevent foam material from covering the hooks, ensuring effective binding and embedding within the foam, thus enhancing the adhesive force and reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional adhesive fastener with uniform hook density is used in foam molding, then the manufacturing process is simple, but the adhesive force is insufficient and the fastener easily loosens from the foam material
Solution Approach 1:
The fastener employs non-uniform hook distribution with different densities in different regions: a first density in the central region and a second density (higher than the first) in the peripheral region. This local quality variation ensures that hooks are strategically positioned to prevent foam material from covering them while maintaining effective binding, thereby resolving the contradiction between sufficient adhesive force and structural simplicity.
2Reliability
If an opening end mold with a retaining wall is used to prevent foam material from covering hooks, then the hooks are protected, but the device complexity increases and production costs rise
Solution Approach 1:
The retaining wall structure is extracted and replaced by the peripheral region of hooks themselves, which naturally form a blocking zone that prevents foam material from flowing toward and covering the central hooks. This eliminates the need for additional mold components while maintaining hook protection, resolving the contradiction between reliability and device complexity.
3Ease of manufacture
If the adhesive fastener is disposed in the mold without a retaining wall, then the manufacturing process is simpler, but the foam material covers the hooks and the adhesive force becomes insufficient
Solution Approach 1:
The peripheral hooks are preliminarily arranged to form a blocking zone that proactively prevents foam material from flowing toward the central hooks during the molding process. This preliminary arrangement ensures that when foam material is filled without a retaining wall, it naturally stops at the peripheral region and does not cover the central hooks, maintaining adhesive force while simplifying the manufacturing process.
Data Source
AI summary
An adhesive fastener for foam molding and cushion thereof are disclosed herein. The adhesive fastener comprises a strip. The strip comprises a surface with a plurality of first hooks and second hooks. The first hooks are disposed on an adhesive area and the second hooks are disposed on a surrounding area of the adhesive area. The arrange density of the first hooks is greater than the arrange density of the second hooks. Therefore, when the adhesive fastener is used in a foam material cushion, the adhesive and fastening function in the adhesive area is working normally and a combining force between the adhesive fastener and the foam material is performed well.