Surface Fastener Thickness Control via Differential Pressing
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Solution Overview
Problem
The existing methods for manufacturing surface fasteners face challenges in reducing the thickness of the base part while maintaining uniformity in the thickness direction, leading to defects such as slack or wavy wrinkles, and increased manufacturing costs due to the need for die renewal.
Innovation Solution
A method involving a molding step to create a pre-fastener body with engaging elements, followed by a thickness-adjusting step where the pre-fastener body or deformed fastener body is pressed to adjust the thickness dimension, allowing for differential reduction of stem portions of engaging elements by applying varying pressing forces across different positions in the cross direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If a uniaxial drawing process is performed to reduce the thickness of the base part, then the thickness of the base part is reduced, but the total thickness dimension varies in the width direction causing defects such as slack or wavy wrinkles
Solution Approach 1:
The patent applies different pressing forces to different regions of the engaging elements based on their position in the width direction. Specifically, engaging elements in the central region are pressed with a greater force than those in the lateral regions, creating a non-uniform pressing force distribution that compensates for the non-uniform thickness reduction caused by the drawing process. This local differentiation of pressing intensity resolves the thickness uniformity issue without requiring die renewal.
2Ease of manufacture
If the thickness of the base part is reduced to increase flexibility and reduce cost, then manufacturing cost is reduced, but manufacturing precision deteriorates due to thickness variation and defects
Solution Approach 1:
The patent changes the pressing force parameter as a function of position in the width direction. By making the pressing force a variable parameter rather than a constant, the process can compensate for the non-uniform thickness reduction. The pressing force is set to be greater in the central region and smaller in the lateral regions, which compensates for the greater thickness reduction in the center and achieves uniform total thickness across the width direction.
3Manufacturing precision
If differential pressing forces are applied to adjust thickness uniformly, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent employs a pressing mechanism where the pressing force can be dynamically adjusted across different regions. The pressing device includes a pressing member that can apply varying forces to different positions in the width direction, allowing the system to adapt to the non-uniform thickness distribution caused by the drawing process. This dynamic capability enables precise control of the total thickness uniformity without requiring complex multiple pressing stages or tool changes.
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 enables stable manufacture of surface fasteners with controlled thickness dimensions across different positions in the width direction, preventing defects and reducing manufacturing costs by avoiding the need for frequent die renewal.
Implementation Method 1
a thickness-adjusting step of adjusting, after the molding step, a thickness dimension of the surface fastener by pressing the pre-fastener body or a deformed fastener body in which at least a portion of the pre-fastener body is subject to at least once deformation process
Implementation Method 2
heating at a temperature lower than or equal to a melting point of the synthetic resin the pre-fastener body or the deformed fastener body with at least one of the upper thickness-adjusting roller and the lower thickness-adjusting roller
Data Source
AI summary
A method of manufacturing a surface fastener. The method includes a molding step of molding a pre-fastener body including the plurality of engaging elements; and a thickness-adjusting step of adjusting, after the molding step, a thickness dimension of the surface fastener by pressing in the thickness direction the pre-fastener body or a deformed fastener body. The thickness-adjusting step includes varying an amount of reduction in a thickness dimension of the stem portion between at least two of the engaging elements by applying respectively different pressing forces to the at least two engaging elements. The method enables stable manufacture of a surface fastener with a total thickness dimension thereof being appropriately controlled at different widthwise positions.