Resin Hook-and-Loop Fastener Integration for Durable Ceiling Fixing
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Solution Overview
Problem
Conventional methods for attaching ceiling materials to vehicle bodies using hook-and-loop fasteners face challenges such as low engaging force, durability issues, and productivity problems, especially when using adhesives or hot melt adhesives, which can lead to falling engaging elements and require additional processing steps.
Innovation Solution
A resin molded body with a hook-and-loop fastener is created by integrating a non-foamed resin molded body with a male-type molded hook-and-loop fastener, where the resin is composed of polyester elastomer or polyamide, and the engaging elements are designed with specific geometries and materials to enhance engaging force and durability, allowing for integration without delamination and improved temperature resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fabric-based male-type hook-and-loop fastener is used, then the engaging force does not decrease even if engagement and peeling are repeated, but the engaging force itself is low and is not suitable for fixing a ceiling material requiring high engaging force
Solution Approach 1:
The patent combines a resin base plate with resin engaging elements to create a composite structure that integrates the durability of resin materials with the mechanical interlocking capability of hook-and-loop fasteners, achieving both high engaging force and repeated engagement durability
Solution Approach 2:
The patent changes the material parameter from fabric to resin and modifies the engaging element geometry (thickness, height, shape) to optimize the balance between engaging force and durability for ceiling material fixation
2Reliability
If a pressure-sensitive adhesive or adhesive is used to attach the hook-and-loop fastener, then the fastener can be attached to the ceiling material, but it requires strong adhesive force at high and low temperatures and over long periods, and curing is required which deteriorates productivity
Solution Approach 1:
The patent replaces the chemical bonding system (adhesives requiring curing) with a mechanical integration system where the fastener and ceiling material are bonded through melting or ultrasonic welding, eliminating the need for curing and improving productivity
Solution Approach 2:
The patent changes the bonding mechanism from chemical adhesion to thermal or mechanical bonding, altering the attachment parameter from adhesive strength to melting temperature or ultrasonic energy, thereby eliminating curing time and improving assembly productivity
3Ease of manufacture
If a hot melt adhesive is used to attach the hook-and-loop fastener, then the fastener can be attached by melting, but the base plate is easily softened by heat generated when the hot melt adhesive is melted, causing the male-type engaging elements to fall down
Solution Approach 1:
The patent applies a heat-resistant coating or selects heat-resistant resin materials for the base plate before the hot melt adhesive bonding process, providing thermal protection that prevents softening and engaging element fall-off during attachment
Solution Approach 2:
The patent modifies the thermal parameters by selecting materials with higher melting points or lower thermal conductivity, and adjusts the bonding process parameters (temperature, time, pressure) to prevent base plate softening while achieving adequate adhesive bonding
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 solution provides a resin molded body with excellent engaging force and durability, maintaining adhesive strength across various temperatures and reducing the risk of engaging element fall-off, while improving productivity by eliminating the need for curing and minimizing environmental impact.
Implementation Method 1
a resin molded body with a hook-and-loop fastener, which is formed by integrating a non-foamed resin molded body and a male-type molded hook-and-loop fastener
Data Source
AI summary
The present invention provides a resin molded body with a hook-and-loop fastener excellent in engaging force, and a method for producing the same. In addition, the present invention provides a method for fixing a ceiling material for automobiles to a vehicle body, which has an adhesive force for a long period of time even under high temperature or low temperature conditions, is excellent in productivity, and does not cause a problem such as falling of a male-type engaging element even when a hot melt adhesive is used. A resin molded body with a hook-and-loop fastener, which is formed by integrating a non-foamed resin molded body and a male-type molded hook-and-loop fastener, wherein the male-type molded hook-and-loop fastener has at least a base plate, a plurality of male-type engaging elements rising from a front surface of the base plate, and a plurality of embedded elements rising from a back surface of the base plate, wherein a resin constituting the male-type molded hook-and-loop fastener is at least one selected from polyester elastomer and polyamide, and the resin molded body and the male-type molded hook-and-loop fastener are integrated by embedding at least a part of the embedded elements in the resin molded body.