Embroidered Loop Fasteners on Base Sheet
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Solution Overview
Problem
Existing methods for manufacturing articles with integrated loops, such as hook-and-loop fasteners, often require additional layers that increase bulk and weight, whereas the goal is to create lighter and more flexible products with efficient manufacturing processes.
Innovation Solution
The method involves using an embroidery machine to create loops directly on a base sheet without an intermediate fastener base sheet, where threads are bonded to the base sheet and a soluble bobbin thread is used to form loops that can be dissolved, allowing for varied patterns, densities, and colors, and the base sheet itself supports the loops, eliminating the need for an extra layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional methods are used to manufacture articles with integrated loops, then the loops can be formed using existing fastener base sheets, but additional layers increase bulk and weight
Solution Approach 1:
The patent combines the base sheet and fastener loops into a single integrated structure. The embroidery machine directly forms loops on the base sheet material itself, eliminating the need for separate fastener base sheets and reducing the number of layers required in the final product.
Solution Approach 2:
The patent extracts and eliminates the intermediate fastener base sheet layer from the traditional multi-layer construction. By using soluble bobbin thread that dissolves away, the process removes unnecessary material while leaving only the required loop structures attached to the base sheet.
2Ease of operation
If traditional fastener base sheets are used, then loops can be manufactured with established processes, but the articles become less flexible and more bulky
Solution Approach 1:
The base sheet and loop structure are merged into a single integrated component. The embroidery process directly attaches loops to the base sheet material, creating a unified structure that eliminates additional layers and reduces overall material bulk while maintaining flexibility.
3Device complexity
If soluble bobbin thread is used to form loops, then loops can be created without intermediate layers, but the manufacturing process requires additional steps
Solution Approach 1:
The soluble bobbin thread is pre-installed in the embroidery machine's bobbin mechanism before the embroidery process begins. This preliminary setup allows the loops to be formed automatically during the embroidery operation, with the bobbin thread being pulled through and then dissolving away to leave clean loop structures without requiring additional post-processing steps.
4Weight of moving object
If loops are embroidered directly on the base sheet, then the article becomes lighter and more flexible, but manufacturing precision requirements increase
Solution Approach 1:
The soluble bobbin thread acts as an intermediary material during the embroidery process. It temporarily holds the loop structure in place during formation and can be precisely controlled by the embroidery machine's bobbin mechanism. After embroidery, the bobbin thread dissolves away, leaving precisely formed loops attached to the base sheet without requiring high-precision direct attachment methods.
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
This approach results in lighter, more flexible articles with integrated loops that can be used as functional fasteners or decorative elements, offering a wide range of patterns and colors while maintaining the base sheet's integrity and reducing material bulk.
Implementation Method 1
a soluble bobbin thread is used to form loops that can be dissolved
Implementation Method 2
threads are bonded to the base sheet
Data Source
Figure 1~1A
Figure 2
Figure 3
AI summary
A method of manufacturing an article may include loading a soluble bobbin thread into an embroidery machine and then driving a needle thread through a base sheet with a needle of the embroidery machine according to a programmed first pattern that provides a series of loops of the needle thread extending outward from a bobbin side of the base sheet. The method may further include bonding the needle thread to a needle side of the base sheet opposite from the bobbin side. A spacer layer may be disposed at the bobbin side of the base sheet, and may be removed after the needle thread is bonded to the base sheet. The loops may be loops of a hook-and-loop fastener or ball control features in various articles manufactured according to the method.