Hook Fastener Tape Ultrasonic Welding Splice Design

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Traditional methods for joining hook fastener tape, such as using staples or mechanical fastening mechanisms, result in waste, increased costs, and gaps that allow foam intrusion in applications like automotive seat covers.

Innovation Solution

Ultrasonic welding is used to splice together hook fastener tapes, with splicing components configured to minimize deformation and foam intrusion by shaping the connecting portion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If staples or mechanical fastening mechanisms are used to join hook fastener tapes, then the tapes can be connected together, but waste is generated and costs increase

Engineering Contradiction:

Improveconnection reliabilityVSAvoidmaterial waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent merges the joining function and the fastener function into a single integrated structure. The connecting portion is formed as an integral part of the hook fastener tape itself, eliminating the need for separate staples or mechanical fasteners. This merging eliminates material waste from separate fastening components while maintaining reliable connection between tape pieces.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The hook fastener tape is designed to join itself through its own structural features. The connecting portion incorporates hook elements that engage with loop elements on adjacent tape pieces, allowing the tape to perform its own fastening function without requiring external fastening mechanisms. This self-service approach eliminates waste from separate fasteners.

Inventive Principle:

Principle #25Self-service

2Reliability

If staples or mechanical fastening mechanisms are used to join hook fastener tapes, then the tapes can be connected together, but extra material and process steps are introduced

Engineering Contradiction:

Improveconnection reliabilityVSAvoidprocess complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the fastener structure and joining mechanism into a single integrated component. The connecting portion is formed as part of the tape manufacturing process itself, eliminating separate fastening steps and reducing overall process complexity while maintaining reliable connections.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The tape structure inherently provides its own joining capability through integrated hook and loop elements in the connecting portion. This eliminates the need for separate fastening operations, reducing process steps and complexity while ensuring reliable attachment between tape pieces.

Inventive Principle:

Principle #25Self-service

3Reliability

If staples or mechanical fastening mechanisms are used to join hook fastener tapes, then the tapes can be connected together, but gaps are created that allow foam intrusion

Engineering Contradiction:

Improveconnection reliabilityVSAvoidfoam intrusion

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent creates a seamless integrated structure where the connecting portion is formed as a continuous extension of the tape. This merging eliminates gaps between tape pieces that would otherwise allow foam intrusion, while the integrated hook-loop engagement maintains reliable connection.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connecting portion is formed as a flexible continuous structure that conforms to the mold cavity without creating gaps. This flexible connection maintains intimate contact with the mold surface, preventing foam intrusion while allowing the necessary mechanical engagement for reliable joining.

Inventive Principle:

Principle #30Flexible shells and thin films

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 ultrasonic welding method eliminates waste and extra costs by directly joining tapes without gaps, reducing the likelihood of foam intrusion and ensuring a smooth, strong connection.

Implementation Method 1

the tapes are spliced together by ultrasonic welding

Methodology Applied

Scientific EffectUltrasonic welding: Ultrasonic Vibration

Implementation Method 2

the component influences the profile of the connecting portion along which the two tapes are joined

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS10405615B2Systems and methods for joining hook fastener structures

Publication Date: 2019.09.10 YKK CORP

AI summary

Systems and methods for joining two or more pieces of hook fastener tape. In some embodiments, the two or more pieces of tape are spliced together using ultrasonic welding. At least one of the splicing components used to splice the tapes together may be configured so that the component influences the profile of a connecting portion along which the two tapes are welded together. In some cases, at least one of the splicing components may be configured to minimize deformation of the tapes as they are welded together.