Keel-Mounted Zipper Structure for Automated Case Body Assembly
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Solution Overview
Problem
Existing zipper cases face high production costs, labor costs, high defective rates, and low efficiency due to manual stitching, with the zipper structure affecting the case's strength and aesthetics.
Innovation Solution
A zipper structure with a keel fixed to the case body, using modular assembly and automated production, featuring a keel within a recess to enhance strength and aesthetics, and a mold operation method for efficient manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual stitching is used to attach zipper to case body, then assembly flexibility is maintained, but production efficiency is low and labor costs are high
Solution Approach 1:
The patent replaces the mechanical stitching system with a chemical bonding system using adhesive. The adhesive layer is applied between the zipper body and case body, eliminating the need for manual stitching operations. This substitution enables automated production lines while maintaining assembly quality, directly resolving the contradiction between production efficiency and automation level.
2Reliability
If manual stitching is used to attach zipper to case body, then assembly adaptability is maintained, but defective rate is high
Solution Approach 1:
The patent replaces manual stitching with adhesive bonding, which provides more consistent and reliable attachment. The adhesive process eliminates variables associated with manual needle and thread operations, such as uneven stitching depth, missed stitches, and thread breakage. This results in lower defective rates while the simplicity of the adhesive application process maintains ease of manufacture.
3Strength
If traditional zipper assembly with leather strip is used, then aesthetic appearance is improved, but case body strength at opening is reduced
Solution Approach 1:
The patent extracts the leather strip element from the traditional zipper assembly and replaces it with a integrated adhesive-bonded zipper body. This removal of the separate leather strip eliminates the height difference that caused aesthetic issues, while the adhesive bonding provides a flush, integrated appearance that maintains both strength and aesthetics.
Solution Approach 2:
The patent merges the zipper body, leather strip function, and aesthetic surface into a single integrated component. The zipper body is directly bonded to the case body with adhesive, eliminating the need for separate leather strips and creating a unified structure that maintains case body strength while achieving superior aesthetic appearance through flush surfaces.
4Ease of manufacture
If manual stitching is used, then skill flexibility is maintained, but labor cost is high
Solution Approach 1:
The patent replaces the complex manual stitching operation with a simple adhesive application process. Instead of requiring skilled stitchers to manually needle and thread through fabric layers, the operation is simplified to applying adhesive and pressing the zipper body into place. This substitution dramatically reduces labor costs while the simplicity of the new operation makes it easily learnable and repeatable.
Data Source
AI summary
A zipper structure, a case body, a mold for manufacturing a case body, and a mold operation method. The zipper structure is for connecting an upper housing and a lower housing of a case body. The zipper structure includes two zipper bodies, each zipper body including a zipper fabric and a keel; an end of the zipper fabric is arranged with first zipper teeth, and the other end of the zipper fabric is configured to be connected to a lining fabric of the case body; the first zipper teeth of one of the two zipper bodies are configured to be engaged with the first zipper teeth of the other of the two zipper bodies; the keel is connected to the zipper fabric; each zipper body is fixed to the case body by fixedly connecting the keel to the case body.