Soft Signage RF Welding Keder Attachment

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Solution Overview

Problem

The existing methods for applying a keder to a fabric for soft signage are labor-intensive and hinder the recycling of fabric, as the keder must be removed by separating it from the sewing thread and fabric.

Innovation Solution

A method involving RF welding to attach a strip of meltable material (keder) to a substrate, such as a polyester fabric, allowing the keder to be easily removed and facilitating recycling, while reducing labor and production time.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If sewing is used to attach the keder to the fabric, then the keder can be securely attached to the fabric, but the process becomes labor-intensive and difficult to remove

Engineering Contradiction:

Improveattachment strengthVSAvoidmanufacturing labor intensity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent replaces the mechanical sewing system with a thermal welding system. RF energy is used to melt and fuse the keder material to the fabric, eliminating the need for needles, threads, and manual sewing operations. This substitution dramatically reduces labor intensity while maintaining secure attachment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the attachment method from mechanical (sewing) to thermal (welding). By controlling the RF energy parameters, the keder material is melted and fused to the fabric at specific temperatures, creating a strong bond that is nonetheless removable by reheating, thus resolving the contradiction between strong attachment and ease of removal.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If sewing is used to attach the keder to the fabric, then the keder remains securely attached during use, but removal requires labor-intensive separation of thread from fabric

Engineering Contradiction:

Improveattachment reliabilityVSAvoidremoval ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent utilizes phase transitions of the keder material. During installation, RF energy heats the keder above its melting point, causing it to melt and fuse to the fabric for secure attachment. During removal, the same process is reversed by reheating to melt the keder again, allowing it to be easily separated from the fabric without damaging the fabric itself.

Inventive Principle:

Principle #36Phase transitions

Solution Approach 2:

The patent replaces mechanical threading and unthreading operations with thermal cycling. The RF welding system provides both attachment and removal functions through controlled heating, eliminating the need for manual thread separation and significantly easing the removal operation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If traditional sewing methods are used, then the keder is securely attached, but production time increases

Engineering Contradiction:

Improveattachment strengthVSAvoidproduction speed

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The patent replaces slow manual or automated sewing processes with rapid RF welding. The RF energy instantly melts and fuses the keder to the fabric in seconds, compared to the minutes required for sewing operations. This dramatically increases production speed while maintaining or improving attachment strength.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The RF welding process allows for continuous attachment of keder to fabric without the stop-start nature of sewing operations. The energy is applied continuously along the length of the keder, enabling faster production while ensuring consistent attachment strength throughout.

Inventive Principle:

Principle #20Continuity of useful action

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 method reduces labor costs and time in producing soft signage, enables easier removal and recycling of the fabric, and ensures a seamless, wrinkle-free appearance of the signage.

Implementation Method 1

The strip of material is welded to the substrate using RF welding

Methodology Applied

Scientific EffectRF welding: Dielectric Heating

Implementation Method 2

The strip of material is melted into the substrate proximate a substrate edge and solidified

Methodology Applied

Scientific EffectSolidification: Freezing

Data Source

PatentUS20250078689A1Soft signage display

Publication Date: 2025.03.06 THE IMAGINE GRP LLC

AI summary

A soft signage, or soft signage piece, is disclosed. The soft signage comprises a display and a frame. The display comprises a substrate and a strip of material. The display is sized to fit tightly within the frame. The substrate may be a natural or synthetic material. In some embodiments, the substrate is a polyester fabric. The fabric has a graphic printed on at least one side thereof. The graphic may extend edge to edge of the fabric. The display includes a strip of material attached along the substrate edges using welding. The strip of material may be referred to as a keder. In some embodiments, the welding comprises RF welding. The display, comprising a printed substrate and welded strip of material, may comprise a silicon edge graphic (SEG). The frame may be formed in any suitable shape and size and includes a recessed groove or slot for receiving the strip of material on the substrate. The frame may comprise any suitable material such as, for example, extruded aluminum.