Resin Fastener Molding With Segmented Deposition and Pressure Control
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Solution Overview
Problem
Existing methods for molding fastener elements on flexible substrates are inefficient in forming discrete resin regions and integrating them into cavities to create arrays of projections, often leading to issues like roll deflection and uneven pressure distribution.
Innovation Solution
A method involving multiple resin dispensers spaced along the processing direction to form discrete resin regions, which are then forced into molding cavities using pressure nips, allowing for staggered and continuous resin islands or lanes, with controlled heating and cooling to ensure proper adhesion and solidification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If discrete resin regions are molded on a flexible substrate using conventional methods, then fastener elements can be formed, but roll deflection and uneven pressure distribution occur leading to poor manufacturing precision
Solution Approach 1:
The molding process is segmented into multiple discrete resin deposition zones along the substrate width, with each zone having its own resin source and corresponding mold cavity. This segmentation allows independent control of resin placement in different regions, enabling precise compensation for roll deflection and uneven pressure distribution without requiring complex global adjustment mechanisms.
Solution Approach 2:
The patent applies local quality by allowing different regions of the substrate to have different resin deposition characteristics. Each local region can be optimized for its specific conditions (e.g., varying pressure, temperature, or resin flow rate) to compensate for roll deflection variations across the width of the substrate, thereby achieving uniform resin integration despite the flexible nature of the material.
2Productivity
If multiple resin sources are used to form discrete resin regions, then productivity increases, but device complexity increases
Solution Approach 1:
The resin dispensing system employs multiple resin sources that can function independently or in combination, providing multi-functionality. Each resin source can serve as a standalone deposition unit or work cooperatively with adjacent sources to create continuous or patterned resin regions. This universal design allows the system to maintain high productivity through parallel operation while managing complexity through modular architecture where each unit follows the same design principles.
3Productivity
If resin is deposited as the substrate moves, then continuous production is achieved, but control precision of resin placement decreases
Solution Approach 1:
The system incorporates feedback mechanisms that monitor substrate position, resin flow rate, and deposition quality in real-time during continuous motion. This feedback allows dynamic adjustment of resin dispensing parameters to compensate for variations in substrate speed or position, maintaining high placement accuracy despite the continuous production environment. The feedback loop ensures that each resin region is accurately placed according to the predetermined pattern.
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 enables efficient formation of resilient fastener elements with controlled pressure distribution, reducing roll deflection and ensuring uniform resin integration, resulting in high-quality fastener products with varied shapes and properties.
Implementation Method 1
depositing molten resin directly onto either the substrate or a surface in which the cavities are defined
Implementation Method 2
forcing resin of at least some of the regions into molding cavities to form a respective array of resin projections
Implementation Method 3
forcing resin of at least some of the regions into molding cavities
Implementation Method 4
controlled heating and cooling to ensure proper adhesion and solidification
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A method of molding resin (16) on a flexible substrate (14) includes forming discrete regions (18,18') of resin (16) and forcing resin (16) of at least some of the regions (18,18') into molding cavities (11) to form a respective array of resin projections (l7a) extending from a resin base (15a,15b) of the regions (18,18'). Forming the discrete regions (18,18') of resin (16) includes depositing molten resin (16) directly onto either the substrate (14) or a surface in which the cavities (11) are defined. The resin (16) is deposited as the substrate (14) moves in a processing direction (24), and the resin (16) is deposited by resin sources (12,12a,12a',12b,12b',12c,13,13a,13b) spaced from each other along the processing direction (24).