U.S. patent application number 10/036446 was filed with the patent office on 2002-05-16 for molded surface fastener, and molding method and molding apparatus of the same.
This patent application is currently assigned to YKK Corporation. Invention is credited to Murasaki, Ryuichi.
Application Number | 20020056176 10/036446 |
Document ID | / |
Family ID | 11751869 |
Filed Date | 2002-05-16 |
United States Patent
Application |
20020056176 |
Kind Code |
A1 |
Murasaki, Ryuichi |
May 16, 2002 |
Molded surface fastener, and molding method and molding apparatus
of the same
Abstract
Molten resin material is continuously extruded from an extruding
hole including a plurality of engaging-element-molding portions
disposed with a constant pitch in a width direction of an extruding
nozzle and a substrate-molding portion with which lower ends of the
engaging-element-molding portions communicate. An
ascending/descending member disposed at a front face of the
extruding nozzle and made of a laterally long plank ascends and
descends to vertically open and close the extruding hole of the
extruding nozzle. As a result of such continuous molding, a surface
fastener is continuously molded in which each of plurality engaging
elements has stem and an engaging extruding head projecting at
least toward one side from an end of the stem standing on a surface
of a flat substrate. The engaging element thus molded has a
thickness, in a direction perpendicular to a projecting direction
of the engaging head, gradually increasing from a top portion of
the engaging head to a base end of the stem. With such engaging
elements that can be molded with a not conventional but new shape
in various sizes, and its molding method and apparatus, maintenance
and management are easy and productivity is high.
Inventors: |
Murasaki, Ryuichi;
(Toyama-ken, JP) |
Correspondence
Address: |
FINNEGAN, HENDERSON, FARABOW, GARRETT &
DUNNER LLP
1300 I STREET, NW
WASHINGTON
DC
20005
US
|
Assignee: |
YKK Corporation
|
Family ID: |
11751869 |
Appl. No.: |
10/036446 |
Filed: |
January 7, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10036446 |
Jan 7, 2002 |
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09594049 |
Jun 14, 2000 |
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|
09594049 |
Jun 14, 2000 |
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09235008 |
Jan 21, 1999 |
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Current U.S.
Class: |
24/442 ; 264/167;
425/380 |
Current CPC
Class: |
Y10T 24/2792 20150115;
Y10T 24/275 20150115; A44B 18/0061 20130101; B29C 48/302 20190201;
A44B 18/0049 20130101; B29C 48/12 20190201; B29C 48/08 20190201;
Y10T 24/27 20150115; B29C 48/07 20190201; Y10T 24/2775 20150115;
B29C 48/13 20190201 |
Class at
Publication: |
24/442 ; 264/167;
425/380 |
International
Class: |
B29C 047/00 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 22, 1998 |
JP |
10-10498 |
Claims
What is claimed:
1. A molded surface fastener comprising a flat substrate and a
large number of engaging elements integrally molded with the flat
substrate, wherein each of the engaging elements has a stem
standing on a surface of the flat substrate and an engaging head
projecting from an end of the stem toward at least one side
thereof, and a thickness of each of the engaging elements in a
direction perpendicular to a projecting direction of the engaging
head gradually increasing from a top of the engaging head to a base
end of the stem.
2. A molded surface fastener according to claim 1, wherein the
engaging head projects in a direction perpendicular to a molding
direction of the molded surface fastener.
3. A molded surface fastener according to claim 1, wherein the flat
substrate has a recessed groove which extends continuously in a
direction perpendicular to a projecting direction of the engaging
head between the engaging elements which are adjacent to each other
in the projecting direction of the engaging head.
4. A molded surface fastener according to claim 1, wherein the flat
substrate has a recessed groove which extends continuously in a
projecting direction of the engaging head between the engaging
elements which are adjacent to each other in a direction
perpendicular to the projecting direction of the engaging head.
5. A molded surface fastener according to claim 1, wherein an end
of the engaging head faces a surface of the flat substrate.
6. A molded surface fastener according to claim 1, wherein a large
number of the engaging elements are disposed in a large number of
lines in a molding direction of the substrate, and the engaging
elements adjacent across the lines are disposed in a staggered
manner.
7. A method for molding a surface fastener integrally molding a
flat substrate and a large number of engaging elements by
continuous molding, wherein said method comprises the steps of
continuously extruding molten resin material from an extruding hole
extending in a width direction of an extruding nozzle, and
vertically opening and closing the extruding hole of the extruding
nozzle by an ascending/descending member disposed in front of the
extruding nozzle, in which the extruding hole comprises a plurality
of engaging-element-molding portions disposed with a constant pitch
in the width direction of the extruding nozzle and a
substrate-molding portion with which lower ends of the
engaging-element -molding portions communicate, the
ascending/descending member is made of a laterally long plank, and
at least a portion of the substrate-molding portion is open when
the extruding hole is at a closed position.
8. An apparatus for molding a surface fastener for integrally
molding a flat substrate and a large number of engaging elements by
continuous molding, wherein said apparatus comprises an extruding
nozzle having an extruding hole extending in a width direction
thereof, an ascending/descending member disposed in front of the
extruding nozzle for vertically opening and closing the extruding
hole, and a driving means for vertically moving the
ascending/descending member, in which the extruding hole comprises
a plurality of engaging-element-molding portions disposed with a
constant pitch in the width direction of the extrusion nozzle and a
substrate-molding portion with which lower ends of the
engaging-element-molding portions communicate, the
ascending/descending member is made of a laterally long plank, and
at least a portion of the substrate-molding portion is open when
the extruding hole is at a closed position.
9. An apparatus for molding a surface fastener according to claim
8, wherein the driving means has a crank mechanism connected
through a link.
10. An apparatus for molding a surface fastener according to claim
8, wherein the driving means has a cam mounted to a rotating shaft
and a cam contact which abuts on the cam.
11. An apparatus for molding a surface fastener according to claim
8, wherein the extruding nozzle has first and second extruding
holes disposed symmetrically and independently on upper and lower
portions of the extruding nozzle.
12. An apparatus for molding a surface fastener according to claim
8, wherein the ascending/descending member comprises first and
second pectinate planks having opening portions formed in a
longitudinal direction thereof so as to correspond to the
engaging-element-molding portions such that the opening portions do
not overlap each other, and the first and second
ascending/descending members are disposed in front and in rear to
face the extruding hole and to alternately ascend and descend by
the driving means.
13. An apparatus for molding a surface fastener according to claim
12, wherein the first ascending/descending member is made of a flat
plate, a non-opening portion of the second ascending/descending
member is in such a shape that the non-opening portion fits into
the opening portion of the first ascending/descending member, and a
vertical length of the opening portion of the first
ascending/descending member is equal to or larger than a sum of a
length of the non-opening portion of the second
ascending/descending member and an ascending/descending amount of
the non-opening portion.
14. An apparatus for molding a surface fastener according to claim
12, wherein the adjacent engaging-element-molding portions of the
extruding hole are alternately disposed in front and in rear, the
opening portion of the first ascending/descending members slidably
fit on the engaging-element-molding portion that is projecting
forward, and a non-opening portion of the second
ascending/descending member is slidably in contact with a front
face of the forward-projecting engaging-element-molding portion.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a molded surface fastener
made of thermoplastic synthetic resin material and having engaging
elements molded integrally with a surface of a flat substrate and
independently of each other, and specifically, to a molded surface
fastener which can be molded in various sizes, ranging from a fine
size to a normal size, which is suitable for various usage in many
fields, and which can be molded continuously and efficiently
through a single step by using a simple apparatus. This invention
also relates to a molding method and a molding apparatus of the
same molded surface fastener.
[0003] 2. Description of the Related Art
[0004] Conventional molded surface fastener is produced by various
methods. A typical example is a method for producing a surface
fastener by complete batch process by injection molding. Another
typical method is a process for molding engaging elements
successively and integrally with a flat substrate by rotating in
one direction a die wheel having on its peripheral face a large
number of cavities for molding the engaging elements and
continuously introducing molten resin material into the peripheral
face of the die wheel. By these methods, various conventionally and
widely known shapes of engaging elements such as a palm shape and a
hook shape can be molded.
[0005] Furthermore, another know method employs an extrusion die in
which a large number of substantially T-shaped extruding openings
are arranged side by side and have lower ends communicating with
each other. By extruding molten resin simultaneously through the
extruding openings, a plurality of ribs which are substantially
T-shaped in section are successively molded on a surface of a flat
substrate. Then, the molten resin molded material is hardened by
cooling. Thereafter, the ribs are successively cut in a
perpendicular direction or in a direction with an appropriate
inclination angle with respect to a horizontal plane where the ribs
are arranged such that each of the cut ribs have a predetermined
thickness. At this time, the flat substrate is left uncut. After
the cutting process, the flat substrate is drawn in a direction of
molding, until the cut engaging elements are separated from each
other with a desired pitch, thereby producing the molded surface
fastener.
[0006] According to the above molding methods, the shape or the
size of the engaging elements is limited, if their productivity is
high, while a continuous molding is difficult to achieve or a
number of processes increases so that the productivity is
decreased, if the shape or the size of the engaging elements is
optional to some extent. Both the cases have extreme advantages and
disadvantages.
[0007] Particularly, in the above process wherein the ribs of the
molten resin molded material having ribs extruded from the
extrusion die to the surface of the flat substrate are cut and the
substrate is drawn, a sectional shape of an engaging head of each
engaging element can be optical to some extent. However, three
steps, i.e., an extrusion molding, cutting of ribs, and drawing are
required. Specifically, a high processing accuracy is required
especially to cut the ribs, so that maintenance and management for
this purpose requires considerable workload and time.
SUMMARY OF THE INVENTION
[0008] The present invention has been accomplished to solve the
above problems, and specifically, it is an object of the invention
to provide a molded surface fastener which can be continuously
molded by an entirely new molding mechanism and which has engaging
elements molded to have new shapes which are not conventional and
of various sizes so that maintenance and management can be easy to
achieve and a productivity is high. It is also an object of the
invention to provide a molding process and a molding apparatus of
the molded surface fastener.
[0009] The above object is achieved by the invention stated
below.
[0010] According to a first aspect of the present invention, there
is provided a molded surface fastener comprising a flat substrate
and a large number of engaging elements integrally molded with
substrate, wherein each of the engaging elements has a stem
standing on a surface of the flat substrate and an engaging head
projecting from an end of the stem toward at least one side
thereof, a thickness of each of the engaging elements in a
direction perpendicular to a projecting direction of the engaging
head gradually increasing from a top of the engaging head to a base
end of the stem.
[0011] With the molded surface fastener of the present invention
having the above shape, the engaging elements do not easily fall
due to a force (shearing force) in a direction parallel to the
surface of the flat substrate or an urging force from above in a
oblique direction with respect to the substrate. Also, when the
loops which are companion engaging elements are pulled obliquely
upward in an engaged state with the stems, the loops are
necessarily guided to boundary areas between the stems and the
engaging heads, thereby preventing rising of the engaging heads in
the loops and preventing the loops from being easily detached from
the stems. On the other hand, because a thickness of each engaging
head in a direction perpendicular to the projecting direction
thereof is formed to gradually increase from its top portion to its
end portion, the engaging elements can easily enter a group of the
opposed loops, and further each engaging element can spread each
loop sideways at the time of entering. Therefore, although the
width of the engaging head gradually increases toward its
projecting end, the engaging head can be easily inserted into the
loop. Further, the engaged companion loop is not easily detached
due to a gouged shape of a neck portion of the engaging element
which is a boundary between the engaging head and the stem thereof,
as compared with the conventional molded surface fastener wherein
the width of the engaging head is constant in the direction,
thereby increasing an engaging rate, an engaging force, and a
peeling force.
[0012] According to the present invention, the engaging head may
project in a direction perpendicular to a molding direction of the
molded surface fastener. Because the surface fastener of this shape
can be continuously molded by a manufacturing process and a
manufacturing apparatus, which will be described later, without
producing a specially shaped molding die for engaging elements with
a special shape. Therefore, a productivity is remarkably
increased.
[0013] According to the present invention, it is preferable that
the flat substrate has recessed grooves which extend continuously
in a direction perpendicular to a projecting direction of the
engaging head between the engaging elements which are adjacent to
each other in the projecting direction of the engaging head.
[0014] Alternatively, the flat substrate has recessed grooves which
extend continuously in a projecting direction of the engaging head
between the engaging elements which are adjacent to each other in a
direction perpendicular to the projecting direction of the engaging
head.
[0015] The above two types of the recessed grooves may be formed to
be perpendicular to each other.
[0016] By forming the recessed grooves in the surface of the
substrate, an apparent thickness of the flat substrate can be
decreased so that flexibility of the surface fastener can be
increased and generation of a crack in the substrate between the
adjacent engaging elements can be prevented. Furthermore, because
side wall faces of the recessed grooves can function as guide faces
for guiding the companion loops to the rising base portion of the
engaging elements, the engaging rate of the engaging elements with
the companion loops can be increased.
[0017] According to the present invention, an end of the engaging
head faces a surface of the flat substrate. With this shape, in
addition to the above-described functions and effects, even if the
engaged companion loops are pulled upward, the loops are not easily
detached from the engaging heads, thereby further increasing the
engaging force as compared with a case where the engaging heads
linearly project from the stems.
[0018] According to the present invention, it is preferable that a
large number of the engaging elements are disposed in a large
number of lines in a molding direction of the flat substrate and
the engaging elements adjacent across the lines are disposed in a
staggered manner. With this arrangement of the engaging elements,
the engaging elements are engaged with companion loops not
regularly but entirely at random, thereby remarkably improving the
engaging rate.
[0019] The molded surface fasteners with the above shapes can be
efficiently molded by the following molding process according to
the present invention.
[0020] According to a second aspect of the present invention, there
is provided a method for molding a surface fastener for integrally
molding a flat substrate and a large number of engaging elements by
continuous molding and comprising the steps of continuously
extruding molten resin material from an extruding hole extending in
a width direction of an extruding nozzle, and vertically opening
and closing the extruding hole of the extruding nozzle by an
ascending/descending member disposed in front of the extruding
nozzle, wherein the extruding hole is in a unitary form comprising
a plurality of engaging-element-molding portions disposed with a
constant pitch in the width direction of the extruding nozzle and a
substrate-molding portion with which lower ends of the
engaging-element-molding portions communicate, the
ascending/descending member is made of a laterally long plank, and
at least a portion of the substrate-molding portion is open when
the extruding hole is at a closed position.
[0021] With this method, the molded surface fasteners having the
above shapes can be continuously produced by a single process so
that a cost of manufacture per a unit can be reasonable. On the
other hand, in order to produce the molded surface fastener similar
in shape to the one of the conventional extrusion molding, a large
number of ribs each having a T shape in cross section, which is to
be formed to stand on the surface of the substrate, are cut in a
longitudinal direction with a predetermined thickness, and then the
substrate is drawn in the longitudinal direction. Because a
plurality of manufacturing processes are required, the conventional
extrusion molding is not efficient. Also, because longitudinal
front and rear faces of the engaging elements of the produced
molded surface fastener are cut, planes of the front and rear faces
are parallel to each other. Therefore, as compared with the above
shape of the engaging elements according to the present invention,
it is natural that the conventional engaging elements are liable to
fall in the front and rear direction, and the cost of manufacture
per a unit is necessarily increased.
[0022] This molding method is carried out by a molding apparatus of
the present invention having the following structures.
[0023] According to a third aspect of the present invention, there
is provided an apparatus for molding a surface fastener for
integrally molding a flat substrate and a large number of engaging
elements by continuous molding and comprising an extruding nozzle
having an extruding hole extending in a width direction thereof, an
ascending/descending member disposed in front of the extruding
nozzle for vertically opening and closing the extruding hole, and a
driving means for vertically moving the ascending/descending
member, wherein the extruding hole comprises a plurality of
engaging-element-molding portions disposed with a constant pitch in
the width direction of the extrusion nozzle and a substrate-molding
portion with which lower ends of the engaging-element-molding
portions communicate, the ascending/descending member is made of a
laterally long plank, and at least a portion of the
substrate-molding portion is open when the extruding hole is at a
closed position.
[0024] In order to mold the surface fastener with the above shapes
by using the molding apparatus of the invention having the above
structure, molten resin extruded from an extruder is extruded from
the extruding hole of the extruding nozzle. At this time, the
ascending/descending member vertically reciprocates in a sliding
contact with a front face of the extruding nozzle simultaneously
with the extrusion. The descending-limit position of the
ascending/descending member is at a position such that a thickness
of the substrate is left below, for example. In other words, flat
molten resin is constantly extruded from the substrate-molding
portion of the extruding nozzle while the ascending/descending
member ascends and descends to the descending-limit position,
thereby successively molding the engaging elements at predetermined
intervals and integrally with an upper face of the flat
substrate.
[0025] Specifically, when a lower end of the ascending/descending
member reaches to its the descending-limit position, i.e., to the
upper face of the flat substrate extruded continuously, the
ascending/descending member starts to ascend to open the openings
of the engaging-element-molding portions upward from the lower ends
thereof. At this time, the molten resin is continuously extruded
from a lower portion according to a degree of opening of the
opening and along shapes of the openings. When the
ascending/descending member reaches upper ends of the openings,
substantially first halves of the engaging elements in the
extruding direction are molded. Then, the ascending/descending
member starts to descend to gradually closing the openings of the
engaging-element-molding portions from the upper ends thereof, and
second halves of the engaging elements are gradually molded from
the top portions of the engaging heads to the rising base ends of
the stems, reversely to the above molding of the first halves.
[0026] A front shape of each engaging element substantially
conforms to a shape of the opening of the engaging-element-molding
portion. On the other hand, side faces of the engaging element are
in such a shape that a width in the molding direction increases
from an upper end toward a lower end thereof. Furthermore, if a
curve of an ascending/descending speed of the ascending/descending
member is changed and controlled in various manners, front and back
curved faces of the engaging element formed by the increasing width
of the side faces of the engaging element in the molding direction
can be changed in various manners. The shape of the side faces is
determined according to the ascending/descending speed of the
ascending/descending member.
[0027] Therefore, by only providing the ascending/descending member
for vertically opening and closing the extruding hole and the
driving means for vertically moving the ascending/descending member
to a front face of the conventional extrusion molding apparatus of
the molded surface fastener of this type, the surface fastener
having such a shape of the engaging element and functions/effects
that can not be anticipated in the above conventional molded
surface fastener of this type can be obtained. Also, an efficient
manufacture by a single step which can not be expected in the
conventional process can be achieved.
[0028] According to the present invention, regardless of the
ascending/descending member having such a simple structure, a most
efficient and highly reliable driving means is provided.
Specifically, the driving means comprises a crank mechanism
connected through a link. Alternatively, the driving means is a cam
driving mechanism having a cam mounted to a rotating shaft and a
cam contact which abuts on the cam.
[0029] According to the present invention, because the extruding
nozzle has first and second extruding holes disposed symmetrically
and independently on upper and lower portions of the extruding
nozzle, thereby doubling a productivity. Moreover, in general,
there is a tendency for molten resin of an amount larger than a set
value to be extruded in a moment at the time when the
ascending/descending member starts to open the extruding hole and
when a pressure of the resin at the extruding hole is high, which
influences on a shape of a front face of the molded engaging
elements. In the present embodiment, however, when either groups of
the upper or lower engaging-element-molding portion starts to open,
the other groups of engaging-element-molding portions start to
close. Therefore, an opening rate of the extruding hole is
constant, so that the resin pressure of the molten resin supply
channel is always maintained at a constant value, and the shapes of
front and rear portions of the engaging elements can be molded as
previously set.
[0030] It is preferable that the ascending/descending member
comprises first and second pectinate planks having opening portions
formed in a longitudinal direction thereof so as to correspond to
the engaging-element-molding portions of the first and second
pectinate planks such that the opening portions do not overlap each
other, and the first and second planks are disposed in the front
and rear to face the extruding hole and alternately ascend and
descend by the driving means. The surface fastener thus molded
comprises a large number of engaging elements arranged in a
staggered manner and standing integrally with the surface of the
flat substrate, as shown in FIG. 10, thereby increasing an engaging
rate of the engaging elements with the companion loops as mentioned
above.
[0031] Specifically, in a molding apparatus for molding the
engaging elements in the staggered manner, the first
ascending/descending member is made of a flat plate, a non-opening
portion of the second ascending/descending member is in such a
shape that the non-opening portion fits into the opening portion of
the first ascending/descending member, and a vertical length of the
opening portion of the first ascending/descending member is
substantially twice as large as that of the non-opening portion of
the second ascending/descending member. Further, it is preferable
that the adjacent engaging-element-molding portions of the
extruding hole are alternately disposed in the front and rear, the
opening portions of the first ascending/descending member are
slidably fit on the engaging-element-molding portions that are
projecting, and a non-opening portion of the second
ascending/descending member are slidably in contact with front
faces of the projecting engaging-element-molding portions.
[0032] Vibration speed may be changed at random. In this case, the
shapes of the engaging elements arranged in the molding direction
can be changed in the same direction. Also, at least one or more
lines of a plurality of engaging-element-molding portions in a
lateral direction perpendicular to the molding direction may be
provided with a height and a shape different from those of the
lines of the other engaging-element-molding portions. In this case,
the plurality of molded engaging elements arranged in a width
direction of the substrate surface have different heights or
shapes. By changing the heights or shapes, it is possible to
appropriately adjust the engaging strength, the engaging rate, the
peeling strength, and the like.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] FIG. 1 is a fragmentary perspective view of a first example
of a molded surface fastener according to the present
invention.
[0034] FIG. 2 is a side view of the molded surface fastener of FIG.
1.
[0035] FIG. 3 is a fragmentary perspective view of a second example
of a shape of the molded surface fastener according to the
invention.
[0036] FIG. 4 is a fragmentary perspective view of a third example
of a shape of the molded surface fastener according to the
invention.
[0037] FIG. 5 is a fragmentary perspective view of a modification
of the molded surface fastener according to the invention.
[0038] FIG. 6 is a fragmentary perspective view of another
modification of the molded surface fastener according to the
invention.
[0039] FIG. 7 is an exploded perspective view of en essential
portion of a first embodiment of a molding apparatus of the surface
fastener according to the invention.
[0040] FIG. 8 is a side view of a molding mechanism, partly broken,
of the surface fastener according to the apparatus of the
invention.
[0041] FIG. 9 is an exploded perspective view of an essential
portion of a second embodiment of the molding apparatus of the
surface fastener according to the invention.
[0042] FIG. 10 is a fragmentary perspective view of the surface
fastener molded by the apparatus of the second embodiment of the
invention.
[0043] FIG. 11 is an exploded perspective view of an essential
portion of a third embodiment of the molding apparatus of the
surface fastener according to the invention.
[0044] FIG. 12 is an exploded perspective view of an essential
portion of a fourth embodiment of the molding apparatus of the
surface fastener according to the invention.
DESCRIPTION OF THE EMBODIMENTS
[0045] Embodiments of the present invention will be described in
detail below based on examples shown in the accompanying drawings.
FIG. 1 is a fragmentary perspective view of a molded surface
fastener having engaging elements, which are in a first typical
shape and FIG. 2 is a side view of the same surface fastener. An
arrow in FIG. 1 shows a direction of molding by a molding apparatus
of the present invention.
[0046] As can be understood from FIGS. 1 and 2, a molded surface
fastener 10 of the present invention can be easily produced by
continuously and integrally molding a flat substrate 11 and a large
number of engaging elements 12 standing on a surface of the
substrate by a single process. Each of the engaging elements 12
comprises a stem 13 directly standing from the surface of the flat
substrate 11 and an engaging head 14 projecting from an end of the
stem 13 sideways in at least one direction. A thickness of the
engaging element 12, which is perpendicular to a projecting
direction of the engaging head 14 of the engaging element 12,
gradually increases from a top portion of the engaging head 14
toward a rising base end of the stem 13.
[0047] As shown in FIGS. 1 and 2, the engaging element 12 of the
present embodiment is formed into a substantially T shape with the
top portion of the engaging head 14 is cut downward in a V-shape
when seen from its front. A width of the stem 13 in a projecting
direction of the engaging head 14 gradually decreases in a rising
direction from the flat substrate 11 and extending in a constant
width from a midway portion up to the engaging head 14. When the
engaging element 12 is seen from a side, as shown in FIG. 2, a
width of the engaging element 12 gradually increases from the top
portion of the engaging head 14 toward the base portion of the stem
13 rising from the flat substrate 11. This
gradually-increasing-width shape is employed not only in the stem
13 but also in the engaging head 14. A thickness of the engaging
head, which is in a perpendicular direction to a projecting
direction of the engaging head 14, gradually increases toward an
end of the engaging head 14, and this gradually-increasing
thickness can be arbitrarily set by changing an
ascending/descending speed of an ascending/descending member 103
which will be described later.
[0048] The surface fastener with the above shape can be easily in a
simple manner by a molding method and a molding apparatus of the
present invention described below. According to the molding method,
all the engaging elements 12 of the invention are molded
independently of each other and integrally with the surface of the
flat substrate 11. Also, as compared with engaging elements
obtained by conventional cutting of ribs and drawing of substrate,
an entire shape of each engaging element 12 is provided with
roundness, thereby remarkably improving a touch of the engaging
elements 12.
[0049] Because each engaging element 12 shown in FIGS. 1 and 2 is
formed such that width dimensions of the stem 13 (in FIG. 1), both
in a front-and-back direction and in a sideways direction,
gradually increase toward the rising base portion, the stem 13 does
not easily fall due to a force (shearing force) in parallel to the
surface of the flat substrate 11 or an urging force from an
obliquely upper direction of the substrate 11. Also, when a loop
(not shown) as an companion engaging element is pulled obliquely
upward while being engaged around the stem 13, the loop is
necessarily guided to a boundary area between the stem 13 and the
engaging head 14. Thus, the engaging head 14 does not rise in the
loop, thereby preventing the loop from being easily detached from
the engaging element 12. On the other hand, because the engaging
head 14 also has a width, which is perpendicular to the projecting
direction of the engaging head 14 (in FIG. 1), gradually increasing
from its top to its end. With such a shape, the engaging elements
12 can easily enter an companion loop group. At this time, each
engaging element 12 presses a companion loop and spreads the loop
sideways. Therefore, the end of each engaging head 14 can be easily
inserted into the companion loop. Also, because a neck portion
which is the boundary portion between the stem 13 and the engaging
head portion 14 is gouged, the companion engaged loop is further
prevented from being easily detached from the engaging element 12,
thereby increasing all of an engaging rate, an engaging force, and
a peeling force, as compared with a conventional engaging element
having a constant width in the same direction.
[0050] A second example of a shape of the engaging element shown in
FIG. 3 is different from the above example in a shape of an
engaging head 14. In other words, the engaging element 12 has only
one engaging head 14. In FIG. 3, the engaging heads 14 project in
either of left or right directions. This direction is determined by
an opening shape of each of a plurality of engaging-element-molding
portions 102a laterally arranged in an extruding hole 102 of an
extruding nozzle 101, which will be described later. For example,
by making the engaging heads 14 project to opposite directions to
each other in each pair of adjacent engaging-element-moldin- g
portions 102a, the engaging elements 12 adjacent to each other in a
direction perpendicular to a molding direction can have adjacent
engaging heads 14 facing opposite directions to each other. It will
be easily understood that this shape example also has the same
functions and effects as those of the engaging elements of the
previous example.
[0051] FIG. 4 shows a third example of a shape of the engaging
element 12. This example is different from the above first shape
example in that the top portion of the engaging heads 14 projecting
left and right directions does not have its center cut downward
into a V shape, but the top portion of the engaging head portion 14
is formed into a simple curved face. With this shape, in addition
to the above functions and effects, even if the engaged companion
loops are pulled upward, the left and right engaging heads 14 do
not easily stand up, thereby further increasing the engaging force,
as compared with the above first shape of the engaging elements
12.
[0052] FIG. 5 shows a first modification of the molded surface
fastener having the engaging elements 12 of the above first element
shape. As shown in FIG. 5, the fastener comprises a large number of
engaging elements 12 molded in lines on the surface of the flat
substrate 11 and recessed grooves 11a continuously formed into a
rectangular sectional shape on the surface of the flat substrate 11
between adjacent lines of the large number of molded engaging
elements 12. FIG. 6 shows a second modification, wherein recessed
grooves 11b having a bow-like sectional are formed in parallel to
the projecting direction of the engaging heads 14 on the surface of
the flat substrate 11 between adjacent front and rear lines of
engaging elements 12. It is also possible to form latticed recessed
grooves by combining the recessed grooves 11a and 11b.
[0053] By forming such recessed grooves 11a or 11b, an apparent
thickness of the flat substrate 11 is decreased so that flexibility
of the surface fastener can be increased and the substrate 11 is
prevented from being easily torn between the adjacent engaging
elements 12. Moreover, because each of side wall faces of the
recessed grooves 11a and 11b each functions as a guide face for
guiding a companion loop to the rising base portion of the engaging
element 12, thereby increasing the engaging rate with the
loops.
[0054] The surface fastener with the above structures are
efficiently produced by a molding apparatus 100 of the present
invention shown in FIG. 7. FIG. 7 shows a first embodiment of the
molding apparatus according to the present invention. In the
molding apparatus of this type, because it is not largely different
from a conventional structure, the extruder is not illustrated in
FIG. 7 and its specific description is omitted here. In FIG. 7, a
reference numeral 101 designates an extruding nozzle mounted to the
extruder (not shown) and the extruding nozzle 101 has an extruding
hole 102 communicating with an inside resin channel. A front end
portion of the extruding nozzle 101 has a vertical face 101a and a
horizontal face 101b horizontally extending forward from the
vertical face 101a. The extruding hole 102 has a laterally long and
narrow substrate-molding portion 102b along a lower end of the
vertical face 101a for molding the flat substrate 11.
Engaging-element-molding portions 102a for molding the engaging
elements 12 open in the vertical face 101a with their lower ends
communicating with the substrate-molding portion 102b.
[0055] The engaging-element-molding portions 102a comprise a
plurality of openings which have lower ends communicating with the
substrate-molding portion 102b and are laterally disposed with a
predetermined pitch. A shape of the individual
engaging-element-molding port on is the same as the first example
of the shape of the engaging element seen from the front. In order
to mold the stems 13 of the engaging elements 12 integrally with an
upper face of the flat substrate 11, the lower ends of molding
opening portions for the stems 13 communicate with the molding
opening portion for the flat substrate 11. In the example shown in
FIG. 7, the extruding nozzle 101 has four engaging-element-molding
portions 102a. The horizontal face 101b of the extruding nozzle 101
constitutes a guide face for guiding a molded product (molded
surface fastener) extruded from the extruding nozzle 101
forward.
[0056] In the present invention, an ascending/descending member 103
is disposed in contact with the vertical face 101a of the extruding
nozzle 101. In the example shown in FIG. 7, the
ascending/descending member 103 is made of a laterally long metal
plank having a wedge-like sectional shape and has a flat face to
abut on the vertical face 101a and a back face opposite to the flat
face which inclines downward toward the flat face to intersect with
the flat face at a lower end of the flat face. A bracket 103a
projects from a center of an upper face of the ascending/descending
member 103 and is connected through a link 105 to a crank shaft 106
which is connected to a rotation-driving source, such as an
electric motor M as shown, for example. Though it is omitted in
FIG. 7, the apparatus includes sliding guide faces at left and
right side edge portions of the vertical face 101a of the extruding
nozzle 101 for allowing the ascending/descending member 103 to
vertically reciprocate.
[0057] Next, it will be described how the molded surface fastener
having the typical shape as shown in FIG. 1 are molded by the
molding apparatus with the above structure. Molten resin extruded
from the extruder (not shown) is extruded from the extruding hole
102 of the extruding nozzle 101 in a shape of the extruding hole
102. At this time, the ascending/descending member 103 vertically
reciprocates in a sliding contact with a front face of the
protruding nozzle 101 simultaneously with the extrusion of molten
resin. According to the embodiment shown in FIG. 7, an
ascending-limit position of the ascending/descending member 103 is
at an upper end position of the engaging-element-molding portion
102a, i.e., an upper end position of the molding opening portions
for the engaging heads 14. A descending-limit position of the
ascending/descending member 103 is at a boundary position between
the engaging-element-molding portions 102a and the
substrate-molding portion 102b, i.e., an upper end position of the
molding opening portion for the flat substrate 11.
[0058] Therefore, during extrusion molding, the molten resin in a
flat shape is constantly extruded from the substrate-molding
portion 102b of the extruding nozzle 102. By the ascending and
descending movement of the ascending/descending member 103, the
engaging elements 12 are successively molded in lines with a
predetermined pitch and integrally with the upper face of the flat
substrate. This will be described in detail now.
[0059] When a lower end of the ascending/descending member 103
reaches its descending-limit position, i.e., the upper face of the
continuously extruded flat substrate 11 and entire openings of the
engaging-element-molding portions 102a are closed, and the
ascending/descending member 103 starts to ascend, the openings of
the engaging-element-molding portions 102a gradually open upward
from their lower ends. At this time, the molten resin is
continuously extruded in accordance with opening degree of the
openings of the engaging-element-molding portions 102a made by the
ascending and descending movement of the ascending/descending
member 103. When the ascending/descending member 103 reaches upper
ends of the openings at last, substantially first halves of the
engaging elements 12 in a extruding direction are molded. Then, the
ascending/descending member 103 starts to descend to close the
openings of the engaging-element-molding portions 102a gradually
from their upper ends, and the second halves of the engaging
elements 12 in the extruding direction are molded gradually from
the top portions of the engaging heads 14 to the rising base ends
of the stems 13, reversely to the above molding of the first
halves.
[0060] By the above molding mechanism, the front shape of each
engaging element 12 substantially conforms to the opening shape of
each of the engaging-element-molding portions 102a. However, a
shape of the side faces of each engaging element 12 is determined
by an ascending/descending speed of the ascending/descending member
103. As shown in FIG. 8, with any speed, the side face of the
engaging element 12 has such a shape that its width in the molding
direction increases from an upper end toward a lower end of the
engaging element 12. Furthermore, by changing and controlling a
curve of the ascending/descending speed of the ascending/descending
member 103, front and rear curved faces of the engaging element 12
formed by the increasing width of the side faces of the engaging
element in the molding direction can be changed in various
manners.
[0061] Thus, every time the ascending/descending member 104 repeats
its ascending and descending movement, a vertical line of a
plurality of engaging elements 12 and the substrate 11 are molded
simultaneously, and the molded surface fastener 10 as shown in FIG.
1 is continuously molded, which comprises the substrate 11 with a
desired length and the lines of desired number of engaging elements
12 disposed in parallel to each other with a predetermined pitch in
the molding direction is successively molded. The molded surface
fastener 10 extruded from the extruding nozzle 101 and continuously
molded is cooled by cooling air or cooling water and sent to the
next step or sent to a winding portion through a feed roller,
though these succeeding steps are omitted in the drawings.
[0062] FIG. 9 shows a second embodiment of the molding apparatus of
the molded surface fastener according to the present invention.
FIG. 10 is a fragmentary perspective view of a portion of the
surface fastener showing an example of arrangement of the engaging
elements 12 molded by the molding apparatus.
[0063] As shown in FIG. 9, the present embodiment comprises an
extruding nozzle 111 having a similar structure to that of the
above first embodiment, a front and rear pair of first and second
ascending/descending member 113, 114 disposed in front of the
extruding nozzle 111, and crank mechanisms 117 and 118 which are
connected through links 115 and 116 to the ascending/descending
members 113 and 114, respectively, and ascend and descend the first
and second ascending/descending members 113 and 114. Other
structures are similar to those in the apparatus of the above first
embodiment.
[0064] According to the present embodiment, similarly to the
apparatus of the above first embodiment, the extruding hole 112 of
the extruding nozzle 111 comprises a plurality of
engaging-element-molding portions 112a and the substrate-molding
portion 112b with which the lower ends of the
engaging-element-molding portions 112a communicate. A total number
of the engaging-element-molding portions 112a is six as designated
by reference numerals {circle over (1)} to {circle over (6)}. On
the other hand, the first and second ascending/descending members
113 and 114 are respectively made of pectinate metal planks each
having two vertically long rectangular slits 113a and 114a.
[0065] Each of the rectangular slits 113a of the first
ascending/descending member 113 basically have a width equal to
that of the rectangular slits 114a of the second
ascending/descending member 114 and is disposed with an interval
which is equal to that of the slits 114a. However, an entire shape
of the first ascending/descending member 113 is different from that
of the second ascending/descending member 114. Specifically, an
upper half portion 113b of the first ascending/descending member
113 has a flat face with a substantially constant thickness, and a
lower half portion 113c of the first ascending/descending member
113 is formed into a wedge-like sectional shape similarly to the
above first embodiment. A height h1 of the rectangular slits 113a
is so large that the slits 113a extend up to near an upper end of
the upper half portion 113b with the constant thickness.
[0066] On the other hand, the second ascending/descending member
114 comprises a constant thickness portion 114b and a wedge-shaped
sectional portion 114c having a wedge-shaped sectional similar to
that of the apparatus of the above first embodiment, the constant
thickness portion 114b being connected to the wedge-shaped
sectional portion 114c by a step through a connecting portion 114d
projecting from a lower end of the constant thickness portion 114b
in a direction reverse to the molding direction. The rectangular
slits 114a of the second ascending/descending member 114 are formed
to reach an upper end of the wedge-shaped sectional portion 114c. A
height h2 of the wedge-shaped portion 114c is set at such a value
that the wedge-shaped portion 114c can be fitted into and can
ascend and descend inside the rectangular slits 113a of the first
ascending/descending member 113 to allow the engaging elements 12
to be formed of the molten resin extruded from the
engaging-element-molding portions 112a.
[0067] The rectangular slits 113a and 114a of the first and second
ascending/descending members 113 and 114 are formed to be displaced
with each other in left or right directions of the first and second
ascending/descending members 113 and 114 such that one do not
overlap the other. The first ascending/descending member 113 is
disposed to be displaced by a pitch of each of the rectangular
slits 113a and 114a relative to the second ascending/descending
member 114, to that the wedge-shaped sectional portion 114c of the
second ascending/descending member 114 is fitted into the
rectangular slits 113a from the front of the first
ascending/descending member 113.
[0068] The first and second ascending/descending members 113 and
114 ascend and descend in contact with the extruding hole 112 of
the extruding nozzle 111 by activating the crank mechanisms 117 and
118 for ascending and descending the first and second
ascending/descending members 113 and 114 connected to the crank
mechanisms 117 and 118 through the links 115 and 116. At this time,
the first and second ascending/descending members 113 and 114 are
alternately driven such that after one of the ascending/descending
members completes its ascending and descending, the other ascends
and descends. For example, when the first ascending/descending
member 113 reaches a descending-limit position, the wedge-shaped
sectional portion 114c of the second ascending/descending member
114 starts to descend inside the rectangular slits 113a of the
first ascending/descending member 113.
[0069] In the example shown in FIG. 9, three lines of engaging
elements 12 are molded from the molten resin extruded from the
odd-numbered engaging-element-molding portions 112a {circle over
(1)}, {circle over (3)}, and {circle over (5)} counted from the
left across the engaging-element-molding portions 112a {circle over
(1)} to {circle over (6)} of the extruding nozzle 111 by using the
first ascending/descending member 113, which three lines of
engaging elements 12 are formed from the molten resin extruded from
the even-numbered engaging-element-molding portions 112a {circle
over (2)}, {circle over (4)}, and {circle over (6)} counted from
the left by using the second ascending/descending member 114. The
molding mechanism is the same as that of the apparatus of the above
first embodiment. The surface fastener thus molded comprises a
large number of engaging elements 12 arranged in a staggered manner
and standing integrally with the surface of the flat substrate 11.
A shape of each the engaging element 12 according to this
embodiment is the same as that shown in FIG. 1.
[0070] FIG. 11 shows a third embodiment of the molding apparatus of
the molded surface fastener. By using this apparatus of the present
embodiment, the surface fastener having the engaging elements 12
disposed in a staggered manner as shown in FIG. 10 can be molded.
The apparatus of the present embodiment is different from the
apparatus of the above second embodiment in structures of the
extruding hole 122 of the extruding nozzle 121, the first
ascending/descending member 123, the second ascending/descending
member 124, the first link 125, the second link 126, and activating
means 127 and 128 for the ascending/descending members 123 and
124.
[0071] The extruding nozzle 121 has a vertical face 121a similar to
the vertical face 101a of the apparatus of the above first
embodiment. Out of a plurality of (five in the example shown in
FIG. 11) engaging-element-molding portions 122a of the extruding
hole 122 defined in the vertical face 121a, the second and fourth
engaging-element-molding portions 122a' {circle over (2)} and
{circle over (4)} are formed to project forward by a thickness
equal to that of the first ascending/descending member 123. The
first ascending/descending member 123 has a lower half portion in a
wedge-like sectional shape made of the pectinate metal plank
including two rectangular slits 123a for sliding with and for being
fitted on the engaging-element-molding portions 122a' so as to be
slidable on the outer side surfaces of the projecting
engaging-element-molding portions. The second ascending/descending
member 124 also has a lower half portion made of the metal plank
comprising left and right wedge-shaped sectional portions 124b
disposed to face the rectangular slits 123a and a rectangular slit
124a formed between the sectional wedge-shaped portions 124b.
[0072] One ends of the first link 125 and the second link 126 are
pivotally mounted to the first and second ascending/descending
members 123 and 124, respectively. Mounted to the other ends of the
first and second links 125 and 126 are rolling members 125a and
126a respectively rolling along ring-shaped cam grooves 127a and
128a of first and second rotating cams 127 and 128 mounted to
respective output shafts of electric motors M which are activating
means for the first and second ascending/descending members 123 and
124.
[0073] In order to mold the surface fastener as shown in FIG. 10
with the above members, the two rectangular slits 123a of the first
ascending/descending member 123 are disposed to be fitted on the
engaging-element-molding portions 122a' projecting forward from the
extruding nozzle 121 so as to be in sliding contact with the left
and right side faces thereof, and the left and right wedge-shaped
sectional portions 124b of the second ascending/descending member
124 are disposed to be in sliding contact with front faces of the
engaging-element-molding portions 122a'. The first and second
ascending/descending members 123 and 124 alternately ascend and
descend in response to rotations of the first and second rotating
cams 127 and 128, thereby continuously molding the surface fastener
having a large number of engaging elements 12 disposed in a
staggered manner on the surface of the flat substrate 11, as shown
in FIG. 10.
[0074] FIG. 12 shows a fourth embodiment of the continuously
molding apparatus for continuously molding the surface fastener
according to the present invention. According to the present
embodiment, the extruding nozzle 131 has a pair of extruding holes
132, 132 formed separately from each other at an upper portion and
a lower portion of a vertical plane 131a respectively. The pair of
upper and lower extruding holes 132, 132 have symmetric shapes with
respect to a center line between the holes 132, 132. The extruding
holes 132, 132 are connected to a single molten-resin-supply
channel (not shown) formed inside the extruding nozzle 131. A shape
of each the extruding hole 132 is the same as that of the extruding
hole of the apparatus of the above first embodiment.
[0075] On the other hand, the ascending/descending member 133 of
the present embodiment comprises a single metal plank in a shape of
an isosceles triangle in section. Crank shafts 137 driven by a pair
of left and right electric motors M, M are respectively connected
to left and right opposite ends of the ascending/descending member
133 through links 136. The ascending/descending member 133 is
disposed such that the member 133 is in contact with the extruding
holes 132 at a flat face side of the ascending/descending member
133. The molten resin is supplied to the extruding nozzle 131 from
the extruder (not shown) and the electric motors M, M are driven to
cause the ascending/descending member 133 to slide upward and
downward through the links 136, thereby continuously molding two
upper and lower surface fasteners. The molding mechanism is the
same as that of the above first embodiment. However, the
ascending/descending member 133 ascends and descends between a
boundary of the upper engaging-element-molding portion 132a and the
corresponding substrate-molding portion 132b and a boundary of the
lower engaging-element-molding portion 132a and the corresponding
substrate-molding portion 132b.
[0076] According to the present embodiment, a productivity doubles.
In the above embodiments, there is a tendency for the molten resin
of an amount larger than a set value to be extruded at a moment
when the ascending/descending member starts to open the extruding
hole and when a pressure of the resin at the extruding hole is
high, which influences on a shape of a front face of each molded
engaging element 12. In the present embodiment, however, when the
upper or lower engaging-element-molding portion 132a starts to
open, the other engaging-element-molding portion 132a starts to
close. Therefore, an opening rate of the extruding holes 132 is
constant, the resin pressure in the molten-resin-supply channel is
always maintained at a constant value, and the shapes of front and
rear portions of the engaging element 12 can be inserted.
[0077] In order to mold the surface fastener having a substrate
structure shown in FIG. 5, the descending-limit position of the
ascending/descending member is not set at the boundary between the
engaging-element-molding portions and the substrate-molding portion
but is set at a midway portion of the stem molding portions of the
engaging-element-molding portions. In contrast, by lowering the
descending-limit position of the ascending/descending member to a
midway position of the substrate-molding portion which is lower
than the boundary between the engaging-element-molding portion and
the substrate-molding portion , the surface fastener having the
substrate structure shown in FIG. 6 can be molded.
[0078] As can be understood from the above description, the
engaging elements 12 of the molded surface fastener according to
the present invention can be individually molded on the flat
substrate 11. In the conventional molded surface fastener, a large
number of lines of ribs each having a shape of the engaging element
in section are extrusion molded together with the substrate to
extend on the substrate, and then the ribs are cut with a
predetermined pitch in a longitudinal direction, and finally the
substrate is drawn to separate the engaging elements from each
other. Compared with such conventional molded fasteners, a touch of
the fastener of the present invention is excellent, and various
arrangements of the engaging elements or various shapes of the
engaging elements 12 on a single substrate can be obtained.
Particularly, according to the present invention, because at least
a width of each engaging element 12, which is in a direction
perpendicular to a projecting direction of the engaging head 14,
gradually increases from a top portion of the engaging head 14 to
the rising base end of the stem 13, the engaging elements can be
prevented from falling and the peeling force and the engaging force
can be increased due to such a peculiar shape of each engaging
elements 12.
[0079] Also, because the surface fastener of the present invention
with the above shape can be continuously molded by a single step by
using the molding process and the molding apparatus of the molded
surface fastener according to the invention, efficiency can be
remarkably increased and a size of a space required for equipment
can be decreased, as compared with the above-mentioned conventional
process and apparatus. Particularly, because the apparatus of the
present invention can be obtained by providing a slight improvement
to the conventional molding apparatus of the same type, cost of
equipment can be decreased.
* * * * *