Hook-and-loop component embedded with foam material and cushion thereof
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Solution Overview
Problem
The existing manufacturing process for hook-and-loop components with foam materials is inefficient and costly due to the need for extra steps to protect the hooks from being covered by the foam, requiring additional manufacturing time and resources.
Innovation Solution
Incorporating a magnetic material on the hook-and-loop component, allowing it to be fixed during the foaming process using a magnet in the mold, ensuring the hooks remain exposed and the foam fills only the designated areas, eliminating the need for extra manufacturing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If extra protective works are included to prevent foam material from covering the hook, then the hook remains exposed, but manufacturing time and cost increase
Solution Approach 1:
The protective structure is extracted from the mold and integrated into the hook-and-loop component itself. The band body is designed with an inherent structure that prevents foam infiltration without requiring separate protective molds or elastic seal portions, thereby reducing manufacturing steps while maintaining hook exposure.
Solution Approach 2:
The band body structure serves its own protective function. The configuration of the band body with the hook-and-loop strip automatically prevents foam material from covering the hook during the foaming process, eliminating the need for external protective measures and reducing manufacturing complexity.
2Manufacturing precision
If extra protective works are included to prevent foam material from covering the hook, then the hook remains exposed, but manufacturing cost increases
Solution Approach 1:
The protective function is extracted from separate mold components and integrated into the band body structure itself. This eliminates the need for special protective molds and elastic seal portions, simplifying the manufacturing process and reducing costs while ensuring proper hook exposure.
Solution Approach 2:
The protective function is merged with the band body structure. The band body is designed to inherently prevent foam infiltration while maintaining hook exposure, combining the structural and protective functions into a single component that reduces overall manufacturing complexity and cost.
3Manufacturing precision
If the hook-and-loop component is fixed during foaming process, then the foam fills only designated areas, but the component requires extra securing steps
Solution Approach 1:
The fixing mechanism is extracted from complex mold structures and replaced with a simple magnetic attachment system. The magnetic material on the band body interacts with the mold's magnetic field to secure the component during foaming, eliminating the need for complicated mechanical fixing mechanisms while ensuring precise foam filling.
4Productivity
If the hook-and-loop component is easily detached from mold, then manufacturing efficiency improves, but securing the component during foaming becomes more difficult
Solution Approach 1:
The mechanical securing system is replaced with a magnetic field-based securing mechanism. The magnetic material on the band body allows for easy attachment during foaming and equally easy detachment after foaming, eliminating the need for complex mechanical releasing mechanisms while improving productivity through simplified operations.
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 reduces manufacturing time and costs by allowing easy detachment of the hook-and-loop component from the mold and ensuring the hooks remain uncovered, while integrating the foam material effectively within the pores of the band body.
Implementation Method 1
the hook-and-loop component with hair loops can be fixed by the magnetic force during the foaming process
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
A hook-and-loop component (1) embedded with a foam material is disclosed herein and includes a band body (10) having a first surface (101) and a second surface (103), the first surface (101) and the second surface (103) being opposite to each other and the hook-and-loop component (1) is characterized in that: a plurality of pores (105) is disposed on the band body (10); a plurality of hair loops (30) is disposed on the first surface (101); and a magnetic material (20) is disposed on the second surface (103) and corresponds to a disposed position of the hair loops (30). The disposed position of the hair loops (30) and the magnetic material (20) includes an interval away from an edge of the first surface (101) and the second surface (103).