Button Shaft Rib Segmentation for Variable Cloth Thickness
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Solution Overview
Problem
Conventional button attachment methods fail to secure sufficient button attachment power and strength across varying cloth thicknesses, often resulting in inadequate formability or excessive radial expansion.
Innovation Solution
A button design featuring a plate-like base portion with radially extending ribs and an upper die with peripheral recesses and projections that allow controlled radial expansion of the shaft, ensuring consistent attachment power regardless of cloth thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the shaft is press-deformed for button-attachment using conventional upper dies, then the shaft is deformed to radially outwardly expand in an entire circumferential direction, but if the cloth is thick, the outward radial expansion of the shaft fails and enough button attachment power and button strength are not secured, while if the cloth is thin, the shaft extends radially outwardly more than required causing a surplus portion that degrades formability
Solution Approach 1:
The shaft's distal portion is segmented into multiple radially extending ribs instead of a uniform cylindrical structure. This segmentation allows different regions of the shaft to deform independently during press-deformation, enabling the ribs to expand radially outwardly in a controlled manner that adapts to varying cloth thicknesses while maintaining both attachment power and formability
Solution Approach 2:
The shaft is designed with non-uniform local properties through the rib structure, where the distal portion has varying radial thickness and structural characteristics along its circumference. This local quality variation enables selective deformation zones that accommodate different cloth thicknesses, ensuring sufficient expansion for thick cloth while preventing excessive expansion for thin cloth
2Force
If the shaft radially outwardly expands sufficiently for thick cloth, then button attachment power is improved, but the shaft extends radially outwardly more than required for thin cloth causing a surplus portion
Solution Approach 1:
The rib structure provides dynamic adaptability during the press-deformation process, allowing the shaft to expand radially to different extents depending on the resistance offered by the cloth thickness. The ribs can deform to achieve sufficient attachment force for thick cloth while naturally limiting expansion for thin cloth, eliminating the need for a surplus portion
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The button attachment method provides improved formability and secure attachment power by allowing controlled radial expansion of the shaft, addressing issues of inadequate strength and excessive deformation across different cloth thicknesses.
Implementation Method 1
an upper die coupled to a pressing machine is moved down towards the lower die, thereby the shaft being swaged through press-deformation by a bottom of the upper die
Implementation Method 2
a plurality of ribs integrally formed with the base portion and onto a surface of the base portion, and radially extending from a center to a circumference of the base portion
Data Source
AI summary
A button includes a button body that is placed over a first main surface of a sheet having the first main surface and a second main surface opposing to the first main surface, the button body having a hole over the first main surface; a fixing member including a base that is placed over the second main surface, and a shaft that projects from the base and passes through the hole from the second main surface towards the first main surface side, in which a distal portion of the shaft includes: a plate-like base portion provided over the button body and covering the hole; and a plurality of ribs integrally formed with the base portion and onto a surface of the base portion, and radially extending from a center to a circumference of the base portion.