Hook-and-Loop Fastener Monofilament Manufacturing Process
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Solution Overview
Problem
Traditional methods for manufacturing hook members of hook-and-loop fasteners are complex and time-consuming, requiring multiple filaments and processes like knitting and side-cutting or thermal melting.
Innovation Solution
A method involving plastic monofilaments formed into loops and flat portions, fused to a substrate using thermal or ultrasonic energy, with loop portions converted into hook elements through side-cutting or thermal melting processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional knitting method with multiple filaments is used, then hook elements can be formed on substrate, but manufacturing process becomes complex and time-consuming
Solution Approach 1:
The patent extracts and eliminates the warp filament from the traditional three-filament knitting system, reducing it to a two-filament system (weft and plastic monofilament). This simplification removes the complexity of coordinating multiple filaments while maintaining the core functionality of forming and securing hook elements on the substrate through the weft knitting process
Solution Approach 2:
Instead of forming hooks directly through complex multi-filament knitting interactions, the patent inverts the approach by first forming simple loops with the plastic monofilament and then converting these loops into hook elements through side-cutting. This inversion simplifies the knitting process while achieving the same functional result
2Productivity
If traditional knitting method is used, then hook elements are formed, but manufacturing time increases
Solution Approach 1:
The patent applies preliminary action by pre-forming loops on the plastic monofilament during the knitting process itself, before the side-cutting conversion to hooks. This preliminary loop formation is integrated into the knitting operation, eliminating separate steps and reducing overall manufacturing cycle time while ensuring proper loop geometry for subsequent hook conversion
3Device complexity
If multiple filaments are used in traditional method, then hook elements can be fixed on substrate, but device complexity increases
Solution Approach 1:
The patent applies multi-functionality to the weft filament, which simultaneously serves multiple roles: (1) forming the knit structure of the substrate, (2) interlocking with the plastic monofilament to secure it, and (3) providing the binding mechanism that fixes the converted hook elements to the substrate. This eliminates the need for a separate warp filament while maintaining reliable fixation through the integrated weft system
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 method simplifies and accelerates the manufacturing process, producing hook elements more conveniently and efficiently, reducing the complexity of traditional methods.
Implementation Method 1
fusing the flat portions of the plurality of plastic monofilaments to the substrate so as to fix the plurality of loop portions of the plastic monofilaments onto the substrate
Implementation Method 2
fusing the flat portions of the plurality of plastic monofilaments to the substrate so as to fix the plurality of loop portions of the plastic monofilaments onto the substrate
Implementation Method 3
performing a thermal melting process to the loop portions at a top end thereof to form hook elements having mushroom-shaped heads
Data Source
AI summary
The present invention provides a novel method for manufacturing a hook member of a hook-and-loop fastener. The method comprises the steps of: providing a plurality of plastic monofilaments (such as polypropylene (PP) monofilaments); forming a plurality of loops on each of the plurality of plastic monofilaments such that each of the plurality of plastic monofilaments has a plurality of loop portions and flat portions between adjacent loop portions; covering the flat portions of the plurality of plastic monofilaments with a web of substrate; fusing the flat portions of the plurality of plastic monofilaments to the substrate so as to fix the plurality of loop portions of the plastic monofilaments onto the substrate; and converting the plurality of loop portions into a plurality of hook elements to thereby producing the hook member that comprises a plurality of hook elements.