Flexible Touch Fastener Coating to Block Seat Foam Intrusion
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Solution Overview
Problem
Existing mold-in fasteners for vehicle seats face challenges in maintaining exposure during the foam molding process, particularly for narrow fastener strips, leading to potential fouling and the need for improved methods to secure seat covers without deep creases or tuck points.
Innovation Solution
A method involving a flexible substrate with a ferromagnetic coating applied to one side, where a resin layer is molded on one side of the substrate, leaving regions exposed, and the ferromagnetic coating extends under both the resin layer and exposed regions, providing a barrier against foam intrusion while allowing the fastener elements to engage with the seat cover.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If narrow fastening strips are used for mold-in fasteners, then the fastener can be securely attached to the foam cushion, but the male touch fastener elements become fouled during the foam molding process
Solution Approach 1:
A ferromagnetic coating layer is applied as an intermediary barrier between the foam and the male touch fastener elements. This coating prevents foam intrusion and fouling of the fastener elements during the molding process, while allowing the fastener to remain securely attached to the cushion
Solution Approach 2:
The patent changes the physical and chemical parameters of the fastener strip by applying a ferromagnetic coating that alters its surface properties. This coating provides foam resistance while maintaining the fastener's mechanical attachment properties to the foam cushion
2Reliability
If deep creases and tuck points are used to secure seat covers, then the cover can be held firmly to the cushion, but the appearance and comfort of the seat are degraded
Solution Approach 1:
The patent extracts the need for deep creases and tuck points by providing a wide fastening area that distributes the retention force across multiple male and female fastener elements. This eliminates the concentration of force that creates unsightly creases while maintaining firm seat cover retention
3Reliability
If wide sheet-form touch fastener products are used, then consistent engagement across wide areas is achieved, but the complexity of maintaining element exposure during molding increases
Solution Approach 1:
The wide fastening area is segmented into multiple discrete male touch fastener elements distributed across the width of the substrate. This segmentation allows each element to be independently exposed and engaged, providing consistent engagement across wide areas while simplifying the molding process control
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 ensures consistent engagement of fastener elements with seat covers across wide areas, prevents wrinkling, and allows for cost-effective, flexible fastening solutions that can conform to complex seat contours.
Implementation Method 1
a flexible ferromagnetic coating bonded to the flexible substrate on a second side and extending under both the resin layer and the exposed region of the first side of the flexible substrate
Data Source
AI summary
A sheet-form fastener product has a flexible substrate such as a lightweight non-woven fabric and a resin layer covering only part of one side of the flexible substrate and leaving a region of the flexible substrate exposed. The resin layer carries multiple touch fastener elements each having a resin stem extending integrally from the layer away from the flexible substrate to an engageable head. A flexible ferromagnetic coating is bonded to the flexible substrate and extends under both the resin layer and the exposed region of the flexible substrate. The resin layer can be arranged as spaced-apart lanes or islands of resin and the coating can be arranged as spaced lanes or islands or otherwise leaving at least a portion of the substrate exposed.