Connector Fastener Array Manufacturing Method

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Solution Overview

Problem

Existing hook and eye fasteners for clothing, such as undergarments and brassieres, have anchors that cause discomfort due to rough edges and increased thickness, leading to aesthetic and tactile issues, and the manufacturing process is complex and costly.

Innovation Solution

A method involving a backing sheet with fasteners like hooks or eyes, where apertures are formed in a sheet portion to receive the fasteners, allowing them to protrude outwardly, with the backing sheet lying between joined sheet portions, and using thermal bonding or ultrasonic welding for assembly, reducing thickness and complexity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If anchors are embedded in the tape to secure fasteners, then the fasteners are firmly attached, but the tape thickness increases and surface becomes rough

Engineering Contradiction:

Improvefastener attachment strengthVSAvoidtape surface smoothness and thickness

Core Design Contradiction:

StrengthVSShape

Solution Approach 1:

The patent extracts the anchor embedding step from the traditional manufacturing process. Instead of embedding anchors directly into the tape, the fasteners are attached to a backing sheet and then the sheet is folded back to create a channel that receives and secures the fastener without embedding anchors in the tape material itself.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces a backing sheet as an intermediary component between the tape and the fastener. This backing sheet serves as the surface to which fasteners are attached, eliminating the need to embed anchors directly in the tape and thus preventing increase in tape thickness and surface roughness.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Shape

If cover strips are sewn over anchors to mask them, then the rough edges and anchors are hidden, but manufacturing complexity and cost increase

Engineering Contradiction:

Improveaesthetic appearanceVSAvoidmanufacturing process complexity

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The patent merges the function of the backing sheet with the cover strip function. The backing sheet is folded back to create a channel that both secures the fastener and provides a smooth surface that masks the anchor area, eliminating the need for separate cover strips and reducing manufacturing steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The backing sheet performs multiple functions: it serves as the attachment surface for fasteners, provides structural support, creates the channel for fastener insertion, and provides a smooth aesthetic surface that masks the anchor area. This multi-functionality eliminates the need for separate cover strips.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If continuous strips of hooks and eyes are severed to produce individual tapes, then the fasteners are separated into usable units, but sharp edges are created that cause discomfort

Engineering Contradiction:

Improvefastener production efficiencyVSAvoidskin irritation from sharp edges

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent extracts the fastener attachment process from the tape manufacturing process. Fasteners are attached to the backing sheet before the sheet is severed into individual tapes, allowing the fasteners to be secured without creating sharp edges on the tape edges themselves.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of creating sharp edges during tape production and then trying to mask them, the patent inverts the approach by securing fasteners to a backing sheet first, then folding the sheet back to create a channel that naturally masks the anchor area without requiring additional cover strips or edge treatment.

Inventive Principle:

Principle #13The other way round (Inversion)

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 solution results in a seamless, comfortable, and aesthetically pleasing fastener system that is easier to manufacture, minimizing discomfort and visibility, while maintaining functionality.

Implementation Method 1

joining the first and second sheet portions such that they are joined along at least two opposing edges common to both the first and second sheet portions

Methodology Applied

Scientific EffectThermal bonding:

Implementation Method 2

using thermal bonding or ultrasonic welding for assembly

Methodology Applied

Scientific EffectUltrasonic welding: Ultrasonic Vibration

Data Source

PatentUS7638009B2Method of manufacturing connector comprising an array of fasteners

Publication Date: 2009.12.29 TEXCO HOOK & EYE TAPE

AI summary

A method of manufacturing a connector by fastening a plurality of the fasteners in an array on a face of a backing sheet and forming an aperture in a first sheet portion for receiving each fastener. Each aperture extends between the opposing first and second surfaces of the first sheet portion. Each fastener is inserted into each respective aperture such that the face of the backing sheet is directed inwardly to lie against the first surface. A second sheet portion is abutted with the second surface and joining the first and second sheet portions such that they are joined along at least two opposing edges common to both the first and second sheet portions. The backing sheet is fixed to the first or second sheet portion and inverting the first and second sheet portions such that the face of the backing sheet is directed outwardly. Each fastener protrudes outwardly from each aperture and the backing sheet lies between the first and second sheet portions.