Helical Hook Fastening Strap for Curved Foam Cushion Grooves
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Solution Overview
Problem
Existing hook-and-loop fastening straps for seat cushions face issues with insufficient bonding force, limited applicability to curved surfaces, and complex, costly manufacturing processes, as they rely on foam penetration and require additional molds for curved grooves.
Innovation Solution
A fastening strap with a hollow helical body formed by folding a plastic hook strap, allowing it to be compressed and securely embedded in U-shaped grooves during foam molding, providing strong bonding and flexibility to bend or curve, eliminating the need for additional molds and intermediate layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional laminated fastening straps with substrate layer, magnetic material layer, hook strap layer and protection layer are used, then the fastening function is provided, but the manufacturing complexity increases and manufacturing costs increase
Solution Approach 1:
The patent combines multiple traditional layers (substrate layer, magnetic material layer, hook strap layer, protection layer) into a single integrated plastic injection-molded component. The hook strap is directly formed on the substrate without requiring separate magnetic material layers or protection layers, simplifying the manufacturing process and reducing structural complexity while maintaining the fastening function.
Solution Approach 2:
The plastic substrate serves multiple functions simultaneously: it acts as the base structure, provides the surface for forming hooks, replaces the need for magnetic material layers, and eliminates the requirement for separate protection layers. This multi-functionality reduces both manufacturing steps and structural complexity.
2Adaptability or versatility
If traditional fastening straps with straight configuration are used, then the manufacturing is simple, but the adaptability to curved fixing grooves is limited
Solution Approach 1:
The patent introduces a bending section with a predetermined curvature radius that allows the fastening strap to adapt to curved fixing grooves. The bending section can be elastically deformed during installation to match different curvature requirements, providing versatility without requiring multiple specialized molds for different curve configurations.
Solution Approach 2:
The patent varies the curvature radius of the bending section to match different fixing groove curvatures. By adjusting this geometric parameter, the same basic fastening strap design can be applied to both straight and curved grooves, enhancing adaptability while maintaining manufacturing simplicity.
3Strength
If traditional fastening straps relying on foam penetration are used, then the structure is simple, but the bonding strength is insufficient
Solution Approach 1:
The patent forms hooks with specific curvature on the surface of the substrate. These curved hooks penetrate the foam material more effectively and provide superior anchoring strength compared to straight or rigid fastening structures. The curvature allows the hooks to engage better with the foam matrix, significantly enhancing bonding strength.
Solution Approach 2:
The patent creates a composite structure where the plastic substrate with integrated hooks works synergistically with the foam material. The hooks penetrate and anchor into the foam, creating a mechanically interlocked composite assembly that provides superior bonding strength compared to simple foam penetration alone.
4Adaptability or versatility
If additional cutting molds with specific curvatures are developed for curved fixing grooves, then the adaptability to curved surfaces is improved, but the manufacturing cost increases
Solution Approach 1:
The patent designs a universal fastening strap with an integrated bending section that can adapt to various curvature requirements through elastic deformation and parameter adjustment. This single versatile design eliminates the need for multiple specialized cutting molds for different curve configurations, significantly reducing tooling costs while maintaining broad applicability.
Solution Approach 2:
Instead of creating different physical molds for each curvature, the patent adjusts the curvature radius parameter of the bending section to match different fixing groove requirements. This parameter-based adaptation allows a single mold design to produce fastening straps suitable for various applications, reducing manufacturing costs while maintaining versatility.
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 offers a strong, cost-effective bonding to seat cushions with both straight and curved grooves, simplifies manufacturing, and enhances applicability by directly integrating with foam articles through hooks, ensuring firm attachment without additional processing.
Implementation Method 1
the hook strap is plastically and permanently deformed at the folding lines to form a hollow helical body
Implementation Method 2
the fastening strap is compressed laterally and is kept in the groove by means of the returning force generated by the configuration of the hollow helical body of the fastening strap and the elasticity of the plastic material
Data Source
AI summary
One aspect of the present invention provides a fastening strap for used in a foam article. The sideway-bendable fastening strap for a foam article includes a substantially flat hollow helical body made from a single hook strap and having a first outer surface, a second outer surface, and a plurality of hooks integrally formed on each of the first and second outer surfaces; wherein the hook strap is formed by plastic injection process and has a substrate and a plurality of hooks integrally formed on one face of the substrate, and wherein the hollow helical body is formed by sequentially and continually folding the hook strap from one end of the hook strap toward the other end of the hook strap along a number folding lines which are parallel with each other and at an angle θ with respect to a longitudinal axis of the hook strap with the face having the hooks formed thereon facing outward such that the hook strap is plastically and permanently deformed at the folding lines to form a hollow helical body having a width w.