Hook-and-loop Fastener Manufacturing Without Non-Resin Molds
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Solution Overview
Problem
Existing methods for manufacturing hook-and-loop fasteners require materials other than resin for destructively-detachable leg molds, leading to disposal issues and potential for defective products due to contact with heaters during melting.
Innovation Solution
A method involving injection molding, cutting, melting, and cooling steps to form hook-and-loop fasteners without using non-resin materials, where the melting step is conducted without contact with a heater to prevent defects, resulting in a unified body with laminated resin layers and semispherical engaging elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a heater is used to melt the tip part of the pillar group during manufacturing, then the engaging portions can be formed, but molten resin may attach to the heater and cause defective products
Solution Approach 1:
A plate-shaped auxiliary mold is introduced as an intermediary between the heater and the pillar group. The auxiliary mold receives heat from the heater and indirectly heats the tip part of the pillar group, preventing direct contact between molten resin and the heater while still achieving the desired melting and shaping of engaging portions.
2Ease of manufacture
If destructively-detachable leg molds are used in the manufacturing process, then the base mold and head mold can be separated, but materials other than resin are required and disposal becomes problematic
Solution Approach 1:
The invention uses only resin material throughout the entire manufacturing process, eliminating the need for destructively-detachable leg molds made of other materials. The resin is injected, molded, and processed uniformly without requiring separation molds made of different materials, thus avoiding material waste and disposal issues.
3Shape
If the tip part of the pillar group is melted to form engaging portions, then the mushroom-shaped engaging elements are created, but the process requires additional materials and complex disposal considerations
Solution Approach 1:
The plate-shaped auxiliary mold serves as a mediator that simplifies the melting process. By heating the auxiliary mold which then heats the pillar group, the process achieves precise control over the melting and shaping of engaging portions without requiring complex direct heating mechanisms or additional materials.
Solution Approach 2:
The invention controls the melting process by adjusting temperature and time parameters. The auxiliary mold is heated to a specific temperature range that allows the tip part of the pillar group to melt and form the desired mushroom shape, while the base plate remains unaffected by the heat.
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 eliminates the need for non-resin materials, allows for easy disposal of cut tip parts, reduces defective products, and produces engaging elements with a less-distorted semispherical shape, enhancing the fastener's performance.
Implementation Method 1
a melting step of melting a tip part of the small pillar group to form pillar body portions which are non-melted portions and engaging portions which are melted portions
Implementation Method 2
a cooling step of cooling the engaging portions to determine shapes of a plurality of engaging elements including the pillar body portions and the engaging portions
Data Source
AI summary
There is provided a hook-and-loop fastener manufacturing method. Injection molding is performed to form a molded product in which a pillar group and a base plate having a surface from which the pillar group protrudes are integrated into a unified body. A tip part of the pillar group is cut to form a cut product in which a small pillar group shorter than the pillar group and the base plate are integrated into a unified body. A tip part of the small pillar group is melted to form pillar body portions which are non-melted portions and engaging portions which are melted portions and thicker than the pillar body portions from small pillars. The engaging portions are cooled to determine shapes of a plurality of engaging elements including the pillar body portions and the engaging portions.