Seamless Hook Tape Ultrasonic Welding Manufacturing
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Solution Overview
Problem
The manufacturing of hook and eye tapes is a complex and cumbersome process, and the use of multiple materials makes recycling difficult, leading to environmental and cost challenges.
Innovation Solution
A seamless hook or eye tape is developed with a laminated body featuring a backing member and a connector, where the connector is securely attached via ultrasonic welding or adhesive, reducing the need for stitching and minimizing the number of materials used, thus simplifying production and enhancing recyclability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional multi-material laminated structure is used for hook and eye tape, then functional requirements (strength, comfort, cushioning) are met, but manufacturing complexity and recycling difficulty increase
Solution Approach 1:
The patent merges multiple functional layers (backing member, cushioning layer, cover layer) into a single integrated tape structure where hooks and eyelets are directly formed on the backing member. This consolidation eliminates the need for separate laminated layers and their associated stitching connections, thereby maintaining functional performance while significantly simplifying manufacturing complexity.
Solution Approach 2:
The backing member is designed to serve multiple functions simultaneously: it provides structural support, directly carries the hooks or eyelets, and eliminates the need for separate cushioning and cover layers in certain embodiments. This multi-functionality approach reduces the overall number of components and simplifies the manufacturing process.
2Reliability
If traditional multi-material laminated structure is used for hook and eye tape, then functional requirements are met, but recycling difficulty and environmental impact increase
Solution Approach 1:
By consolidating multiple materials into a single integrated tape structure, the patent makes the entire assembly recyclable as one unit. The hooks and eyelets are directly formed on the backing member without requiring separate laminated layers, allowing the entire tape to be processed together in recycling streams, thereby improving ease of manufacture for recycling purposes.
3Strength
If wired hooks and eyelets are sewn onto garment, then secure closure is achieved, but manufacturing process becomes cumbersome and time-consuming
Solution Approach 1:
The hooks and eyelets are pre-formed directly on the backing member in a single manufacturing step, eliminating the need for subsequent stitching operations. This preliminary formation of the closure elements ensures secure attachment while dramatically improving manufacturing efficiency by removing time-consuming sewing steps.
Solution Approach 2:
The patent replaces the mechanical stitching process with a direct formation method where hooks and eyelets are created integrally on the backing member. This substitution eliminates the need for needles, threads, and sewing machinery, thereby improving productivity while maintaining closure security.
4Reliability
If multiple layers with different materials are used, then specific physical characteristics are provided, but production costs and recycling efforts increase
Solution Approach 1:
The patent merges multiple material layers into a single integrated structure where the backing member provides all necessary physical characteristics. By forming hooks and eyelets directly on the backing member without requiring separate cushioning and cover layers, the invention reduces recycling time and cost while maintaining the required physical properties for functional performance.
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 seamless construction simplifies the manufacturing process, reduces production costs, and makes the tape more environmentally friendly by making it more recyclable.
Implementation Method 1
the seamless connection further includes an auxiliary seamless connection formed between corresponding portions of the backing member and the cover member at a position peripheral to the main seamless connection; Advantageously, at least one of the main seamless connection and the auxiliary seamless connection comprises a weld; more advantageously, the main seamless connection is a weld that joins the corresponding portions of the backing member and the cover member thereby fixing the position of the first part of the connector on the body; yet more advantageously, the welds are ultrasonic welds formed by way of ultrasonic welding
Data Source
AI summary
A hook or eye tape comprising a body including a backing member; a connector arranged on the body and the connector has a first part; and a main seamless connection formed between the first part of the connector and a corresponding portion of the backing member to secure the connector at a desired position on the body; and the method of making the same.