Snap Fastener Assembly for 3D Decorative Panels

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Solution Overview

Problem

Current methods for producing decorative panels by attaching folded material to a substrate are labor-intensive and costly, limiting production rates due to the need for meticulous handsewing.

Innovation Solution

A method using snap fasteners to securely attach folded, flexible material to a substrate, enabling efficient and cost-effective high-volume production of decorative panels with aesthetic and acoustic value.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If handsewing is used to attach decorative material to substrate, then attachment quality and aesthetic value are improved, but production rate and cost-effectiveness deteriorate

Engineering Contradiction:

Improveattachment qualityVSAvoidproduction rate

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces the manual handsewing mechanical system with an automated snap fastener system. Snap fasteners can be attached using automated machinery, eliminating the need for meticulous handsewing while maintaining secure attachment. This substitution enables high-volume production while preserving attachment quality through consistent mechanical fastening.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the attachment mechanism from a continuous process (handsewing) to a discrete fastening system (snap fasteners). This parameter change allows for standardized, repeatable attachment operations that can be performed rapidly by machines, thereby increasing production rate while maintaining attachment quality through precise snap fastener placement.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If handsewing is used to attach decorative material to substrate, then attachment quality is improved, but manufacturing cost deteriorates

Engineering Contradiction:

Improveattachment qualityVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces the labor-intensive handsewing mechanical system with an automated snap fastener system. This substitution reduces the need for highly skilled labor, lowering labor costs while maintaining attachment quality through consistent mechanical fastening. The automated process also reduces production time, further decreasing manufacturing costs.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention uses snap fasteners as disposable or replaceable fastening elements that can be quickly attached and removed. While individual snap fasteners are simple and inexpensive components, their ability to enable rapid automated assembly significantly reduces overall manufacturing costs compared to expensive handsewing labor, making high-quality attachment more cost-effective.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Productivity

If snap fasteners are used to attach folded material to substrate, then production rate and cost-effectiveness are improved, but attachment complexity increases

Engineering Contradiction:

Improveproduction rateVSAvoidattachment complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent divides the attachment system into separate components: the snap fastener itself and the substrate with pre-attached snaps. This segmentation allows for independent preparation and assembly, simplifying the overall process. The snap fasteners can be pre-attached to substrates in advance, and then folded decorative pieces with corresponding snaps are quickly connected, reducing on-site assembly complexity while maintaining high production rates.

Inventive Principle:

Principle #1Segmentation

4Ease of manufacture

If snap fasteners are used to attach folded material to substrate, then production cost is reduced, but fastening mechanism complexity increases

Engineering Contradiction:

Improveproduction costVSAvoidfastening mechanism complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The invention employs snap fasteners as simple, inexpensive fastening components that can be mass-produced at low cost. While the fastening mechanism involves multiple parts (snap button, socket, and body), each component is simple and inexpensive to manufacture. The overall system complexity is justified by the significant reduction in production costs through automated assembly and reduced labor requirements.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Data Source

PatentUS11912060B1Method of producing decorative articles using snap fasteners

Publication Date: 2024.02.27 DAWSON DONY

AI summary

A method of producing a decorative article using snap fasteners is disclosed. The Method includes selecting a desired sheet of flexible material and a desired substrate; cutting the sheet based on a predetermined template; securing a plurality of snap fasteners to the sheet and to the substrate; folding the cut sheet into a desired three-dimensional shape; securing the desired three-dimensional shaped sheet in place via the plurality of snap fasteners; and coupling the secured three-dimensional shaped sheet to the substrate via the plurality of snap fasteners.