Zipper Attachment Using Folded Single Material
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Solution Overview
Problem
The existing methods for attaching a zipper to a carrying case require measuring and cutting two pieces of material, leading to exposed raw edges that can fray and fail over time, and create a weak point under stress, increasing manufacturing costs and complexity.
Innovation Solution
A single piece of material is used, with opposed raw edges folded to create a double layer that is attached to the zipper tape and then to the case, eliminating exposed edges and reducing assembly steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If two pieces of material are used to attach the zipper, then the attachment strength is improved, but the manufacturing complexity and number of assembly steps increase
Solution Approach 1:
The patent merges two separate pieces of material into a single continuous piece that wraps around the zipper tape. This single piece is folded back on itself to create the necessary double-layer reinforcement at the attachment point, eliminating the need to separately join two pieces while maintaining the required strength
Solution Approach 2:
The single piece of material is folded to create distinct functional zones: a first layer attached to the zipper tape, a folded-back second layer that provides reinforcement, and a third layer that extends to the case. This segmentation allows one continuous piece to perform the function previously requiring two separate pieces
2Strength
If two pieces of material are joined together, then the attachment strength is improved, but the number of assembly steps increases
Solution Approach 1:
The patent combines the function of two separate material pieces into one continuous piece that is folded back on itself. This eliminates the separate assembly step of joining two pieces together, reducing total assembly time while maintaining the reinforced attachment structure
Solution Approach 2:
The material is pre-folded during the cutting stage to create the necessary layers and configuration. This preliminary folding action prepares the material in its final configuration before attachment, eliminating subsequent joining steps that would otherwise be required
3Ease of manufacture
If raw edges are exposed at the attachment point, then the manufacturing process is simpler, but the reliability decreases due to fraying
Solution Approach 1:
The material is folded back on itself to create overlapping layers where the raw edge is enclosed between the first and second layers. This self-enclosure protects the raw edge from fraying without requiring additional protective components or complex finishing processes
Solution Approach 2:
The folded material creates a flexible protective envelope that encloses the raw edge. The thin film structure of the folded layers provides protection against fraying while maintaining the flexibility needed for the attachment to function properly
4Ease of manufacture
If a single piece of material is used, then the manufacturing cost is reduced, but the attachment strength may be compromised
Solution Approach 1:
The single piece of material is folded to create multiple functional layers from one continuous piece. The fold creates overlapping sections where the material reinforces itself, providing attachment strength equivalent to or greater than two separate pieces while using only one material piece
Solution Approach 2:
The solution transitions from a two-piece planar arrangement to a three-dimensional folded structure. By folding the single piece back on itself, the material creates multiple layers and attachment points in space, achieving reinforced strength without requiring multiple separate pieces
Data Source
AI summary
A method of attaching a zipper (42) to a carrying case (40) to define an interior compartment or pocket (60). Opposed edges (52, 54) of a single piece of material (50) are folded under and are sewn to respective top (62) and bottom (64) surfaces of a tape (48) of the zipper to form a double layer of the material (58) extending from the zipper. A fold line (56) is formed in the double layer of material, and the fold line is sewn to the body (44) of the case. Stitching steps are minimized, no raw edge is exposed to the interior volume, and the double layer of material provides strength.