U.S. patent application number 10/216456 was filed with the patent office on 2002-12-19 for continuous molding of fastener products with a mold belt.
This patent application is currently assigned to Velcro Industries B.V., a Curacao. Invention is credited to Babineau, James W., Clune, William, Jens, Stephen C., Provost, George A..
Application Number | 20020190418 10/216456 |
Document ID | / |
Family ID | 22977158 |
Filed Date | 2002-12-19 |
United States Patent
Application |
20020190418 |
Kind Code |
A1 |
Jens, Stephen C. ; et
al. |
December 19, 2002 |
Continuous molding of fastener products with a mold belt
Abstract
Several methods and machines for continuously forming a fastener
product having an array of fastener elements extending from a
continuous, sheet-form base, employing a mold belt on which the
sheet-form base of the product is formed and from which it is
subsequently stripped. The belt defines an array of cavities
extending from its outer surface, for molding either the array of
fastener elements or an array of preform stems that are
subsequently reformed into the fastener elements. In some cases the
cavities are blind, such as for forming hook-type fastener
elements; in other cases, the cavities extend through the belt,
such as for forming mushroom-type fastener elements. Various belt
constructions and fastener element shapes are also disclosed.
Inventors: |
Jens, Stephen C.;
(Winchester, MA) ; Clune, William; (Concord,
NH) ; Provost, George A.; (Litchfield, NH) ;
Babineau, James W.; (Newton, MA) |
Correspondence
Address: |
JAMES W. BABINEAU
Fish & Richardson P.C.
225 Franklin Street
Boston
MA
02110-2804
US
|
Assignee: |
Velcro Industries B.V., a
Curacao
|
Family ID: |
22977158 |
Appl. No.: |
10/216456 |
Filed: |
August 9, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10216456 |
Aug 9, 2002 |
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09257648 |
Feb 25, 1999 |
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6432339 |
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09257648 |
Feb 25, 1999 |
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08920188 |
Aug 25, 1997 |
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Current U.S.
Class: |
264/166 ;
264/167; 425/363; 425/471; 425/814 |
Current CPC
Class: |
A44B 18/0049 20130101;
B29C 2043/3678 20130101; B29L 2031/729 20130101; B32B 37/153
20130101; B29C 45/2675 20130101; B29C 43/46 20130101; Y10S 425/814
20130101; B29C 48/07 20190201; B29C 48/08 20190201; B29C 33/3857
20130101; B29C 48/9145 20190201; B29C 59/025 20130101; B29C 48/35
20190201; B29C 45/0003 20130101; B29C 45/2673 20130101; B29C
2043/465 20130101; B29C 2043/461 20130101; B29C 41/28 20130101;
B29C 33/302 20130101; B29C 2043/023 20130101; B29C 43/222
20130101 |
Class at
Publication: |
264/166 ;
264/167; 425/363; 425/471; 425/814 |
International
Class: |
B29C 033/38; B29C
041/28 |
Claims
What is claimed is:
1. A method of continuously forming a fastener product having an
array of fastener elements extending from a continuous, sheet-form
base, the method comprising providing a mold belt defining a
two-dimensional array of cavities extending from an outer surface
thereof; training the mold belt in a loop about first and second
rolls; introducing molten plastic resin to the outer surface of the
mold belt; forcing the plastic resin into the cavities of the belt
under pressure in a gap to fill the cavities while forming the
sheet-form base of the product on the outer surface of the belt;
solidifying the resin as the resin is carried on the belt; and
stripping the solidified resin from the mold belt, the mold belt
continuing along its loop and returning to the gap.
2. The method of claim 1 wherein the cavities of the belt are
shaped to mold hook-type fastener elements having distal ends
extending toward the sheet-form base.
3. The method of claim 1 wherein the cavities of the belt are
shaped to mold mushroom-type fastener elements having heads
overhanging the sheet-form base in multiple directions.
4. The method of claim 1 wherein the cavities of the belt are sized
to mold fastener elements of less than about 0.050 inch in total
height, as measured from the product base.
5. The method of claim 4 wherein the cavities of the belt are sized
to mold fastener elements of less than about 0.020 inch in total
height, as measured from the product base.
6. The method of claim 1 wherein the mold belt comprises a
belt-form substrate and plating material deposited upon one side of
the substrate in a predetermined pattern to form the fastener
element-shaped cavities.
7. The method of claim 1 wherein the cavities of the mold belt
extend only partially through the mold belt.
8. The method of claim 1 wherein the plastic resin is forced into
the cavities under pressure at a nip defined between the first roll
and a pressure roll.
9. The method of claim 1 further comprising cooling the mold belt
away from the gap.
10. The method of claim 1 wherein the first roll comprises a driven
roll.
11. The method of claim 1 wherein the cavities of the mold belt
extend completely through the mold belt.
12. The method of claim 11 further comprising timing the mold belt
to the first roll such that the cavities of the mold belt align
with dimples in the surface of the first roll, the step of forcing
plastic resin into the cavities including filling the dimples of
the first roll through the aligned cavities to form fastener
element heads while forming corresponding fastener element stems in
the aligned belt cavities.
13. The method of claim 11 further comprising timing the mold belt
to the first roll such that the cavities of the mold belt align
with protrusions extending from the surface of the first roll, the
protrusions extending into the aligned cavities as the resin is
forced into the cavities to form fastener elements with heads
defining top recesses formed by the protrusions.
14. The method of claim 11 wherein the step of stripping the
solidified resin from the mold belt includes passing the belt about
the second roll, the second roll having projections arranged to
push the resin from the belt cavities, the second roll being timed
to the mold belt to align the projections with the belt
cavities.
15. The method of claim 1 wherein the gap is defined between the
first roll and a pressurized extruder.
16. The method of claim 1 further comprising introducing a backing
material to the resin in the gap, whereby the backing material is
laminated to one side of the sheet-form base of the product.
17. The method of claim 1 wherein the gap is defined adjacent the
first roll.
18. The method of claim 1 further comprising cooling the resin as
it is carried on the belt.
19. The method of claim 1 wherein the mold belt comprises metal,
the cavities forming holes extending through the belt.
20. The method of claim 1 wherein the belt comprises solidified
resin molded to define the cavities.
21. The method of claim 1 wherein the belt comprises a series of
rigid mold plates, each mold plate having an exposed edge defining
a row of said cavities, the mold plates spaced apart and held
together by flexible resin in the form of a continuous belt.
22. A method of continuously forming a fastener product having an
array of fastener elements extending from a continuous, sheet-form
base, the method comprising providing a mold belt defining an array
of cavities extending from an outer surface thereof; training the
mold belt about first and second rolls; forcing molten plastic
resin into the cavities of the belt under pressure to fill the
cavities in a pressure region while forming the sheet-form base of
the product on the outer surface of the belt; cooling the resin as
the resin is carried on the mold belt; and thereafter stripping the
cooled resin from the mold belt at a stripping region spaced apart
from the pressure region, the mold belt returning to the pressure
region along a predetermined path.
23. The method of claim 22 wherein the pressure region is defined
between a pressurized extruder and a pressure reaction plate.
24. The method of claim 22 wherein the pressure region is defined
between a pair of rolls, the molten resin being introduced to the
mold belt under atmospheric pressure before being forced into the
cavities in the pressure region.
25. The method of claim 22 wherein the pressure zone is defined
between a pressurized extruder and the first roll, the second roll
being disposed diametrically opposite the pressure zone and
arranged to apply load to the first roll through a load transfer
roll to balance bending loads applied to the first roll by extruder
pressure.
26. A method of continuously forming a fastener product having an
array of fastener elements extending from a continuous, sheet-form
base, the method comprising providing a mold belt defining an array
of holes extending therethrough from one broad surface thereof to
an opposite broad surface thereof; in a pressure region, forcing
molten plastic resin into the holes of the belt under pressure from
the one broad surface while the holes are covered at the opposite
broad surface of the belt by a pressure reaction surface, to fill
the holes while forming the sheet-form base of the product on the
one broad surface of the belt; solidifying the resin as the resin
is carried away from the pressure reaction surface on the mold
belt; and thereafter stripping the solidified resin from the mold
belt at a stripping region spaced apart from the pressure
region.
27. The method of claim 26 wherein the mold belt is in the form of
a continuous loop, the mold belt returning to the pressure region
from the stripping region.
28. The method of claim 26 wherein the resin is solidified by being
cooled while carried on the belt.
29. The method of claim 26 wherein the solidified resin is pushed
from the holes of the belt at the stripping region by aligned
projections extending from a roll about which the belt is
trained.
30. A method of making a mold belt for the continuous molding of a
fastener product having an array of molded fastener elements
extending from a continuous, sheet-form base, the method comprising
providing a mold master surface having an array of projecting, male
fastener elements extending therefrom; casting mold resin about the
fastener elements on the mold master surface; solidifying the mold
resin; and then stripping the solidified resin from the mold master
surface, leaving an array of female cavities extending into the
solidified resin from a surface thereof, the cavities having the
shape of the fastener elements of the mold master surface.
31. The method of claim 30 wherein the resin is cast about
reinforcement elements.
32. The method of claim 31 wherein the reinforcement elements
comprise metal.
33. The method of claim 30 wherein the resin comprises a thermoset
material.
34. The method of claim 30 wherein the fastener elements of the
mold master surface are hook-type fastener elements.
35. The method of claim 30 wherein the step of casting comprises
sequentially forming longitudinal sections of a flexible mold belt
in a section molding cavity, each successive longitudinal section
being formed at an end of a previously formed section.
36. A method of making a mold belt for the continuous molding of a
fastener product having an array of molded fastener elements
extending from a continuous, sheet-form base, the method comprising
providing a continuous, flexible, strip-form belt adapted to be
trained about multiple rolls; and forming an array of holes through
the belt, each hole shaped to form a fastener element having an
overhanging head for engaging loops.
37. The method of claim 36 wherein the belt comprises metal, the
holes being formed through the metal of the belt by an etching
process.
38. The method of claim 37 wherein the step of forming includes
etching through the belt from opposite surfaces thereof to form
holes extending completely through the belt.
39. The method of claim 38 wherein the holes so. formed are shaped
to mold hook-type fastener elements.
40. A method of making a mold belt for the continuous molding of a
fastener product having an array of molded fastener elements
extending from a continuous, sheet-form base, the method comprising
the steps of providing a series of flat mold plates, each mold
plate having an edge and defining a row of fastener element-shaped
cavities extending from the edge; arranging the mold plates in
parallel, spaced apart relation, the edge of each mold plate from
which its cavities extend facing in a common direction; and
injecting elastomeric material into spaces defined between the mold
plates to connect the mold plates and form a flexible length of
belt.
41. The method of claim 40 wherein the mold plates each define
apertures therethrough, the step of injecting including filling the
apertures with the elastomeric material to interconnect elastomeric
material on both sides of each mold plate.
42. The method of claim 41 further comprising, before the step of
injecting, the step of stringing reinforcement wire through the
apertures of adjacent mold plates, the reinforcement wire being
subsequently encapsulated by the elastomeric material.
43. The method of claim 40 further comprising, before the step of
injecting, filling the cavities of the mold plates with a removable
filler to prevent the cavities from filling with elastomeric
material during the injecting step, the method also including,
after the step of injecting, the step of removing the filler from
the cavities.
44. The method of claim 40 wherein the mold plates are composed of
metal.
45. The method of claim 40 wherein the elastomeric material
comprises heat-resistant rubber, silicone or urethane.
46. The method of claim 40 wherein the mold plates each have a
thickness of less than about 0.020 inch, a length of at least about
0.5 inch, and a width, corresponding to mold belt thickness, of
between about 0.040 and 0.25 inch.
47. The method of claim 40 wherein the mold plates are spaced apart
to define interplate gaps of between about 0.005 and 0.025
inch.
48. The method of claim 40 wherein each mold plate has a back edge,
on a side opposite the cavities, exposed on a back side of the belt
for transferring heat from the cavities.
49. An apparatus for continuously molding a fastener product having
an array of fastener elements integrally molded with and extending
from a continuous, strip-form base, the apparatus comprising first
and second rolls; a flexible mold belt defining an array of
fastener element-shaped cavities extending from an outer surface
thereof, the mold belt trained about both said rolls; and a source
of molten plastic resin arranged to deliver resin to the mold belt,
the apparatus constructed to force the plastic resin into the
fastener element-shaped cavities of the belt under pressure in a
gap to mold the array of fastener elements while forming the
strip-form base of the product.
50. The apparatus of claim 49 wherein the cavities of the belt are
shaped to mold hook-shaped fastener elements.
51. The apparatus of claim 49 wherein the cavities of the belt are
sized to mold fastener elements of less than about 0.050 inch in
total height, as measured from the product base.
52. The apparatus of claim 51 wherein the cavities of the belt are
sized to mold fastener elements of less than about 0.020 inch in
total height, as measured from the product base.
53. The apparatus of claim 49 wherein the mold belt comprises a
belt-form substrate and plating material deposited upon one side of
the substrate in a predetermined pattern so as to form the fastener
element-shaped cavities.
54. The apparatus of claim 49 wherein the cavities of the mold belt
extend only partially through the mold belt.
55. The apparatus of claim 49 further comprising a pressure roll
adjacent the first roll, the pressure and first rolls defining
therebetween a nip in which the plastic resin is forced into the
cavities under pressure.
56. The apparatus of claim 49 further comprising a cooling system
adapted to cool the belt away from the gap.
57. The apparatus of claim 49 wherein the mold belt has a thickness
of less than about 1/8 inch.
58. The apparatus of claim 57 wherein the mold belt has a thickness
of less than about 0.050 inch.
59. The apparatus of claim 58 wherein the mold belt has a thickness
of less than about 0.020 inch.
60. The apparatus of claim 49 wherein the mold belt has a width of
at least about 1/2 inch, for molding a fastener product of a
corresponding width.
61. The apparatus of claim 60 wherein the mold belt has a width of
at least about 2 inches, for molding a fastener product of a
corresponding width.
62. The apparatus of claim 61 wherein the mold belt has a width of
at least about 6 inches, for molding a fastener product of a
corresponding width.
63. The apparatus of claim 49 wherein the mold belt consists
essentially of molded thermoset resin.
64. The apparatus of claim 49 wherein the mold belt comprises a
laminate having a layer of metal and a layer of thermoset resin,
the fastener element-shaped cavities being defined in the layer of
thermoset resin.
65. The apparatus of claim 49 wherein the mold belt comprises
molded thermoset resin and reinforcing elements extending the
length of the mold belt.
66. The apparatus of claim 65 wherein the reinforcing elements
comprise cables, wires, mesh, strips or yarns.
67. The apparatus of claim 49 wherein the mold belt consists
essentially of metal, the fastener element-shaped cavities
comprising holes extending through the mold belt between two
opposite broad sides thereof.
68. The apparatus of claim 49 wherein the mold belt comprises a
layer of metal bonded to a layer of elastomeric material, the
elastomeric material being sufficiently soft to enable the
elastomeric material to be radially compressed by cavity pressure
to locally and temporarily enlarge the effective diameter of the
fastener element cavities within the layer of elastomeric
material.
69. The apparatus of claim 49 wherein the mold belt comprises a
series of flat mold plates, each mold plate having an edge and
defining a row of fastener element-shaped cavities extending from
the edge; and elastomeric material separating and interconnecting
the mold plates in parallel, spaced apart relation to form a
flexible length of belt, the edge of each mold plate from which its
cavities extend facing in a common direction.
70. The apparatus of claim 69 wherein the mold plates each define
apertures therethrough, the apertures filled with the elastomeric
material to interconnect elastomeric material on both sides of each
mold plate.
71. The apparatus of claim 70 wherein the mold belt further
comprises reinforcement wire extending through the apertures of
adjacent mold plates and encapsulated within the elastomeric
material.
72. The apparatus of claim 69 wherein the mold plates are composed
of metal.
73. The apparatus of claim 69 wherein the elastomeric material
comprises heat-resistant rubber, silicone or urethane.
74. The apparatus of claim 69 wherein the mold plates each have a
thickness of less than about 0.020 inch, a length of at least about
0.5 inch, and a width, corresponding to mold belt thickness, of
between about 0.040 and 0.25 inch.
75. The apparatus of claim 69 wherein the mold plates are spaced
apart to define interplate gaps of between about 0.005 and 0.025
inch.
76. The apparatus of claim 69 wherein each mold plate has a back
edge, on a side opposite the cavities, exposed on a back side of
the belt for transferring heat from the cavities.
77. The apparatus of claim 49 wherein the mold belt comprises an
array of rigid inserts interconnected by a strip of flexible resin,
each insert defining a corresponding cavity of the array of
cavities.
78. The apparatus of claim 77 wherein the rigid inserts comprise
metal.
79. The apparatus of claim 77 wherein the rigid inserts extend
through the thickness of the mold belt.
80. The apparatus of claim 79 wherein each of the cavities extends
through the thickness of the mold belt.
81. The apparatus of claim 77 wherein surfaces of the inserts
defining the cavities are of stamped form.
82. The apparatus of claim 77 wherein the cavities are shaped to
form mushroom-type fastener elements having overhanging heads at
the distal ends of stems.
83. The apparatus of claim 49 wherein the first roll is driven.
84. The apparatus of claim 49 wherein the source of molten plastic
comprises a pressurized extruder.
85. The apparatus of claim 84 wherein the gap is defined between
the first roll and the pressurized extruder.
86. The apparatus of claim 84 wherein the gap is defined between
the pressurized extruder and a fixed pressure reaction plate.
87. The apparatus of claim 49 constructed to introduce a backing
material to the resin in the gap, whereby the backing material is
laminated to one side of the sheet-form base of the product.
88. The apparatus of claim 49 wherein the gap is defined adjacent
the first roll.
89. The apparatus of claim 49 wherein the cavities of the belt are
defined by etched surfaces.
90. An apparatus for continuously molding a fastener product having
an array of mushroom-type fastener elements integrally molded with
and extending from a continuous, strip-form base, the apparatus
comprising first and second rolls; a flexible mold belt defining an
array of holes extending therethrough, the mold belt trained about
both said rolls; a source of molten plastic resin arranged to
deliver resin to the mold belt, the apparatus constructed to force
the plastic resin into the holes of the belt under pressure in a
gap to mold an array of preform stems while forming the strip-form
base of the product; means of stripping the base and preform stems
from the belt; and means of reforming resin of a distal end of each
preform stem to form an overhanging head on each stem, thereby
forming the array of mushroom-type fastener elements.
91. An apparatus for continuously molding a fastener product having
a wide array of fastener elements extending from a continuous,
strip-form base, the apparatus comprising first and second rolls; a
mold belt defining an array of cavities extending from an outer
surface thereof in at least three rows, the mold belt trained about
both the first and second rolls; a source of molten plastic resin
arranged to deliver resin to the outer surface of the mold belt,
the apparatus constructed to force the plastic resin into the
cavities of the belt under pressure to fill the cavities as the
continuous base of the product is formed on the outer surface of
the mold belt; and means for cooling the resin in the cavities of
the belt to solidify the resin while on the belt; and means for
stripping the cooled resin from the belt, the fastener elements
pulled complete from the belt cavities.
92. The apparatus of claim 91 wherein the source of molten plastic
resin comprises a pressurized extruder.
93. The apparatus of claim 92 wherein the extruder is arranged to
extrude the resin into the cavities of the mold belt in a gap
defined between the first roll and the extruder.
94. The apparatus of claim 92 wherein the extruder is arranged to
extrude the resin into the cavities of the mold belt in a gap
defined between the extruder and a pressure reaction plate disposed
between the first and second rolls.
95. The apparatus of claim 91 wherein the cooling means comprises a
fan arranged to force air across the mold belt.
96. The apparatus of claim 91 wherein the cooling means comprises
coolant circulated through at least one roll about which the mold
belt is trained.
97. The apparatus of claim 91 wherein the cavities of the mold belt
are shaped to form fastener elements having overhanging heads.
98. The apparatus of claim 91 wherein the cavities of the mold belt
are shaped to form fastener element stems, and wherein the first
roll defines an array of cavities at its peripheral surface shaped
to form fastener element heads, the first roll having a series of
pins extending therefrom to engage corresponding holes in the mold
belt for timing the belt with respect to the first roll to align
the cavities of the mold belt with the cavities of the mold roll to
form an array of contiguous fastener element-shaped cavities, the
molten plastic resin filling the array of contiguous cavities at
the first roll to form the array of fastener elements.
99. The apparatus of claim 91 wherein the mold belt is timed to the
first roll such that the cavities of the mold belt align with
protrusions extending from the surface of the first roll, the
protrusions extending into the aligned cavities as the resin is
forced into the cavities to form fastener elements with heads
defining top recesses formed by the protrusions.
100. The apparatus of claim 91 wherein the stripping means
comprises an array of projections extending radially from a
peripheral surface of the second roll, the second roll also having
an array of pins extending radially therefrom for engaging a row of
holes in the mold belt to align the cavities of the mold belt with
the projections, the projections adapted to push the cooled
fastener elements from the cavities of the mold belt.
Description
CROSS-REFERENCE TO PENDING APPLICATIONS
[0001] This is a continuation-in-part of co-pending U.S. Ser. No.
08/920,188, filed Aug. 25, 1997.
BACKGROUND OF THE INVENTION
[0002] This invention relates to the continuous molding of fastener
products, such as those having a multiplicity of miniature
fastening elements extending from a common sheet-form base.
[0003] Touch fastener products have arrays of miniature fastener
elements (for instance, hook-shaped or mushroom-shaped elements)
extending from a common base. Typically, in order to be capable of
engaging a loop fiber or another fastener element, these fastener
elements have overhanging "crooks", such as the hook portion of a
hook-shaped element or the underside of the head of a
mushroom-shaped element. These crooks snag and retain loop fibers,
for instance, to form a fastening, but can be challenging to mold
in their fully functional form in non-opening mold cavities.
[0004] One solution for continuously molding such fastener elements
for touch fasteners and other products was disclosed by Fischer in
U.S. Pat. No. 4,794,028 (the full disclosure of which is hereby
incorporated herein by reference as if fully set forth). In
commercial implementations of his solution, a cylindrical, rotating
mold roll is composed of a large number (e.g., thousands) of thin,
disk-shaped mold plates (or rings) and spacer plates which are
stacked concentrically about a central barrel. Extending inwardly
from the periphery of the mold plates are cavities for molding the
hook elements. Molten resin is introduced to the rotating mold roll
and forced into the cavities to form the fastener elements while a
layer of the resin on the circumference of the roll forms the
integral strip-form base. The mold roll is cooled (e.g., by
circulating a liquid coolant through the barrel) to sufficiently
solidify the fastener elements to enable them to be stripped from
their cavities before making a complete revolution about the mold
roll. Thus, in prior implementations of the Fischer process the
production speeds obtainable for a given diameter mold roll have
been limited by the required "residence time" of the cooling
fastener elements in their cavities to enable successful
withdrawal. Over-chilling the mold roll to reduce the required
residence time can impede proper filling of the cavities by
solidifying the resin as it is forced into the cavities.
[0005] Another implementation of the general Fischer process, also
using stacked mold plates in the form of a multi-plate mold roll
apparatus for continuously molding fastener products is described
by Murasaki et al. in U.S. Pat. No. 5,441,687.
[0006] Multi-plate mold rolls are more prone to bending deflection
caused by molding pressures than solid rolls of similar diameter.
Such bending deflection can result in undesirable base thickness
variation across the width of the fastener product at higher
molding pressures.
[0007] In U.S. Pat. No. 3,594,863 George Erb discloses a different
method and apparatus for molding hook-type fastener elements
without employing a mold roll. Erb forms his hooks in cavities
partially defined by grooves cut into a moving belt, by injecting
molten nylon against the belt (i.e., from the "hook side" of the
resulting product), thereby forming narrow ribbons, each ribbon
having only two rows of hooks, one row extending from each of its
longitudinal edges. To form a useful sheet of fastener product
having an entire two-dimensional array of hooks (i.e., of many rows
of hooks), Erb laminates many individual ribbons to a preformed
base sheet.
SUMMARY OF THE INVENTION
[0008] We have realized that touch fastener products, with either
hook-type or mushroom-type fastener elements integrally molded with
a solid base and arranged in wide arrays, can be formed in a
continuous process by molding the fastener elements and base
together on a moving belt defining an entire array of cavities.
[0009] According to a first aspect of the invention, a method is
provided for continuously forming a fastener product having an
array of fastener elements extending from a continuous, sheet-form
base. The method includes the steps of:
[0010] (1) providing a mold belt defining a two-dimensional array
of cavities extending from an outer surface of the belt;
[0011] (2) training the mold belt in a loop about first and second
rolls;
[0012] (3) introducing molten plastic resin to the outer surface of
the mold belt;
[0013] (4) forcing the plastic resin into the cavities of the belt
under pressure in a gap to fill the cavities while forming the
sheet-form base of the product on the outer surface of the
belt;
[0014] (5) solidifying the resin as the resin is carried on the
belt; and then
[0015] (6) stripping the solidified resin from the mold belt, the
mold belt continuing along its loop and returning to the gap.
[0016] In some embodiments, the cavities of the belt are shaped to
mold hook-type fastener elements having distal ends extending
toward the sheet-form base. In some other embodiments, the cavities
of the belt are shaped to mold mushroom-type fastener elements
having heads overhanging the sheet-form base in multiple
directions.
[0017] Preferably, the cavities of the belt are sized to mold
fastener elements of less than about 0.050 inch in total height, as
measured from the product base (more preferably, less than about
0.020 inch in total height).
[0018] In some embodiments, the mold belt includes a belt-form
substrate and plating material deposited upon one side of the
substrate in a predetermined pattern to form the fastener
element-shaped cavities.
[0019] In some cases, the cavities of the mold belt extend only
partially through the mold belt.
[0020] In some arrangements, the plastic resin is forced into the
cavities under pressure at a nip defined between the first roll
(which may be driven) and a pressure roll.
[0021] In some embodiments, the method also includes cooling the
mold belt away from the gap.
[0022] In some embodiments, the cavities of the mold belt extend
completely through the mold belt.
[0023] For some applications, the method also includes timing the
mold belt to the first roll such that the cavities of the mold belt
align with dimples in the surface of the first roll. The step of
forcing plastic resin into the cavities includes filling the
dimples of the first roll through the aligned cavities to form
fastener element heads while forming corresponding fastener element
stems in the aligned belt cavities.
[0024] In some other embodiments, the method includes timing the
mold belt to the first roll such that the cavities of the mold belt
align with protrusions extending from the surface of the first
roll. The protrusions extend into the aligned cavities as the resin
is forced into the cavities, to form fastener elements with heads
defining top recesses formed by the protrusions.
[0025] In some configurations, the step of stripping the solidified
resin from the mold belt includes passing the belt about the second
roll, the second roll having projections arranged to push the resin
from the belt cavities. The second roll is timed to the mold belt
to align the projections with the belt cavities.
[0026] In some cases, the gap is defined adjacent the first roll,
such as between the first roll and a pressurized extruder.
[0027] In some embodiments, the method includes introducing a
backing material to the resin in the gap, whereby the backing
material is laminated to one side of the sheet-form base of the
product.
[0028] In some cases, the method includes cooling the resin as it
is carried on the belt.
[0029] The mold belt comprises metal in some instances, the
cavities forming holes extending through the belt.
[0030] In some arrangements, the belt includes solidified resin
molded to define the cavities.
[0031] In some embodiments, the belt has a series of rigid mold
plates, each mold plate having an exposed edge defining a row of
the cavities. The mold plates are spaced apart and held together by
flexible resin in the form of a continuous belt.
[0032] According to a second aspect of the invention, a method is
provided for continuously forming a fastener product having an
array of fastener elements extending from a continuous, sheet-form
base. The method includes the steps of:
[0033] (1) providing a mold belt defining an array of cavities
extending from an outer surface thereof;
[0034] (2) training the mold belt about first and second rolls;
[0035] (3) forcing molten plastic resin into the cavities of the
belt under pressure to fill the cavities in a pressure region while
forming the sheet-form base of the product on the outer surface of
the belt;
[0036] (4) cooling the resin as the resin is carried on the mold
belt; and thereafter
[0037] (5) stripping the cooled resin from the mold belt at a
stripping region spaced apart from the pressure region, the mold
belt returning to the pressure region along a predetermined
path.
[0038] In some cases, the pressure region is defined between a
pressurized extruder and a pressure reaction plate. In some other
cases, the pressure region is defined between a pair of rolls, the
molten resin being introduced to the mold belt under atmospheric
pressure before being forced into the cavities in the pressure
region.
[0039] In some instances, the pressure zone is defined between a
pressurized extruder and the first roll, the second roll being
disposed diametrically opposite the pressure zone and arranged to
apply load to the first roll through a load transfer roll to
balance bending loads applied to the first roll by extruder
pressure.
[0040] According to a third aspect of the invention, a method of
continuously forming a fastener product having an array of fastener
elements extending from a continuous, sheet-form base, includes the
steps of:
[0041] (1) providing a mold belt defining an array of holes
extending therethrough from one broad surface of the belt to an
opposite broad surface of the belt;
[0042] (2) in a pressure region, forcing molten plastic resin into
the holes of the belt under pressure from the one broad surface
while the holes are covered at the opposite broad surface of the
belt by a pressure reaction surface, to fill the holes while
forming the sheet-form base of the product on the one broad surface
of the belt;
[0043] (3) solidifying the resin as the resin is carried away from
the pressure reaction surface on the mold belt; and thereafter
[0044] (4) stripping the solidified resin from the mold belt at a
stripping region spaced apart from the pressure region.
[0045] In some embodiments, the mold belt is in the form of a
continuous loop, the mold belt returning to the pressure region
from the stripping region.
[0046] In some cases, the resin is solidified by being cooled while
carried on the belt.
[0047] The solidified resin is pushed from the holes of the belt at
the stripping region, in some embodiments, by aligned projections
extending from a roll about which the belt is trained.
[0048] According to a fourth aspect of the invention, a method of
making a mold belt for the continuous molding of a fastener product
having an array of molded fastener elements extending from a
continuous, sheet-form base, includes the steps of:
[0049] (1) providing a mold master surface having an array of
projecting, male fastener elements extending from the master
surface;
[0050] (2) casting mold resin about the fastener elements on the
mold master surface;
[0051] (3) solidifying the mold resin; and then
[0052] (4) stripping the solidified resin from the mold master
surface, leaving an array of female cavities extending into the
solidified resin from a surface thereof, the cavities having the
shape of the fastener elements of the mold master surface.
[0053] In some cases, the resin is cast about reinforcement
elements which may comprise metal.
[0054] Suitable resins include thermoset materials.
[0055] In some embodiments, the fastener elements of the mold
master surface are hook-type fastener elements.
[0056] In some cases, the step of casting includes sequentially
forming longitudinal sections of a flexible mold belt in a section
molding cavity, each successive longitudinal section being formed
at an end of a previously formed section.
[0057] According to a fifth aspect of the invention, a method of
making a mold belt for the continuous molding of a fastener product
having an array of molded fastener elements extending from a
continuous, sheet-form base, includes the steps of:
[0058] (1) providing a continuous, flexible, strip-form belt
adapted to be trained about multiple rolls; and
[0059] (2) forming an array of holes through the belt, each hole
shaped to form a fastener element having an overhanging head for
engaging loops.
[0060] In some embodiments, the belt comprises metal, the holes
being formed through the metal of the belt by an etching process.
The belt may be etched from opposite surfaces of the belt to form
holes extending completely through the belt.
[0061] In some cases, the holes so formed are shaped to mold
hook-type fastener elements.
[0062] According to a sixth aspect of the invention, a method of
making a mold belt for the continuous molding of a fastener product
having an array of molded fastener elements extending from a
continuous, sheet-form base, includes the steps of:
[0063] (1) providing a series of flat mold plates, each mold plate
having an edge and defining a row of fastener element-shaped
cavities extending from the edge;
[0064] (2) arranging the mold plates in parallel, spaced apart
relation, the edge of each mold plate from which its cavities
extend facing in a common direction; and
[0065] (3) injecting elastomeric material into spaces defined
between the mold plates to connect the mold plates and form a
flexible length of belt.
[0066] In some embodiments, the mold plates each define apertures
therethrough. The step of injecting includes filling the apertures
with the elastomeric material to interconnect elastomeric material
on both sides of each mold plate. In some cases, before the step of
injecting, reinforcement wire is strung through the apertures of
adjacent mold plates, the reinforcement wire being subsequently
encapsulated by the elastomeric material.
[0067] The method includes, in some cases before the step of
injecting, filling the cavities of the mold plates with a removable
filler to prevent the cavities from filling with elastomeric
material during the injecting step. After the step of injecting,
the filler is removed from the cavities.
[0068] In presently preferred embodiments, the mold plates are
composed of metal and the elastomeric material comprises
heat-resistant rubber, silicone or urethane. The mold plates each
have a thickness of less than about 0.020 inch, a length of at
least about 0.5 inch, and a width, corresponding to mold belt
thickness, of between about 0.040 and 0.25 inch, and are spaced
apart to define interplate gaps of between about 0.005 and 0.025
inch.
[0069] In some cases, each mold plate has a back edge, on a side
opposite the cavities, which is exposed on a back side of the belt
for transferring heat from the cavities.
[0070] According to a seventh aspect of the invention, an apparatus
is provided for continuously molding a fastener product having an
array of fastener elements integrally molded with and extending
from a continuous, strip-form base, the apparatus includes first
and second rolls, a flexible mold belt defining an array of
fastener element-shaped cavities extending from an outer surface of
the belt, the mold belt trained about both the rolls, and a source
of molten plastic resin arranged to deliver resin to the mold belt.
The apparatus is constructed to force the plastic resin into the
fastener element-shaped cavities of the belt under pressure in a
gap to mold the array of fastener elements while forming the
strip-form base of the product.
[0071] Various embodiments of the apparatus of the invention
contain one or more of the characteristics described above with
respect to the method aspects of the invention.
[0072] In some embodiments, the apparatus includes a pressure roll
adjacent the first roll, the pressure and first rolls defining
therebetween a nip in which the plastic resin is forced into the
cavities under pressure.
[0073] In some configurations, the apparatus includes a cooling
system adapted to cool the belt away from the gap.
[0074] Presently preferred belts have a thickness of less than
about 1/8 inch (more preferably less than about 0.050 inch, and
even more preferably less than about 0.020 inch), and a width of at
least about 1/2 inch (more preferably of at least about 2 inches,
and een more preferably of at least about 6 inches), for molding a
fastener product of a corresponding width.
[0075] In some cases, the mold belt consists essentially of molded
thermoset resin.
[0076] In some other cases, the mold belt comprises a laminate
having a layer of metal and a layer of thermoset resin, the
fastener element-shaped cavities being defined in the layer of
thermoset resin.
[0077] In yet other cases, the mold belt comprises molded thermoset
resin and reinforcing elements extending the length of the mold
belt. Suitable reinforcing elements include cables, wires, mesh,
strips or yarns.
[0078] In some embodiments, the mold belt consists essentially of
metal, the fastener element-shaped cavities comprising holes
extending through the mold belt between two opposite broad sides of
the belt.
[0079] In some embodiments, the mold belt includes a layer of metal
bonded to a layer of elastomeric material, the elastomeric material
being sufficiently soft to enable the elastomeric material to be
radially compressed by cavity pressure to locally and temporarily
enlarge the effective diameter of the fastener element cavities
within the layer of elastomeric material.
[0080] Some mold belts include a series of flat mold plates, each
mold plate having an edge and defining a row of fastener
element-shaped cavities extending from the edge, and elastomeric
material separating and interconnecting the mold plates in
parallel, spaced apart relation to form a flexible length of belt.
The edge of each mold plate from which its cavities extend faces in
a common direction.
[0081] In some configurations, the mold plates each define
apertures through the plate, the apertures filled with the
elastomeric material to interconnect elastomeric material on both
sides of each mold plate. In some cases, the mold belt includes
reinforcement wire extending through the apertures of adjacent mold
plates and encapsulated within the elastomeric material.
[0082] In presently preferred embodiments, the mold plates are
composed of metal. Suitable elastomeric materials include compounds
of heat-resistant rubber, silicone or urethane. Preferably, the
mold plates each have a thickness of less than about 0.020 inch, a
length of at least about 0.5 inch, and a width, corresponding to
mold belt thickness, of between about 0.040 and 0.25 inch, and are
spaced apart to define interplate gaps of between about 0.005 and
0.025 inch.
[0083] In some other embodiments, the mold belt has an array of
rigid inserts interconnected by a strip of flexible resin, each
insert defining a corresponding cavity of the array of cavities.
Presently preferred insert materials include metal. The rigid
inserts may extend through the thickness of the mold belt, and each
of the cavities may extend through the thickness of the mold belt.
In some cases, surfaces of the inserts defining the cavities are of
stamped form. The cavities may be shaped to form mushroom-type
fastener elements having overhanging heads at the distal ends of
stems.
[0084] In some embodiments, the source of molten plastic comprises
a pressurized extruder. The gap is defined, in some cases, between
the first roll and the pressurized extruder, or between the
pressurized extruder and a fixed pressure reaction plate.
[0085] In some configurations, the apparatus is constructed to
introduce a backing material to the resin in the gap, whereby the
backing material is laminated to one side of the sheet-form base of
the product.
[0086] The cavities of the belt are defined, in some embodiments,
by etched surfaces.
[0087] According to an eighth aspect of the invention, an apparatus
is provided for continuously molding a fastener product having an
array of mushroom-type fastener elements integrally molded with and
extending from a continuous, strip-form base. The apparatus
includes first and second rolls; a flexible mold belt defining an
array of holes extending through the belt, the mold belt trained
about both the rolls; a source of molten plastic resin arranged to
deliver resin to the mold belt; means of stripping the base and
preform stems from the belt; and means of reforming resin of a
distal end of each preform stem to form an overhanging head on each
stem, thereby forming the array of mushroom-type fastener elements.
The apparatus is constructed to force the plastic resin into the
holes of the belt under pressure in a gap to mold an array of
preform stems while forming the strip-form base of the product.
[0088] According to a ninth aspect of the invention, an apparatus
is provided for continuously molding a fastener product having a
wide array of fastener elements extending from a continuous,
strip-form base, the apparatus including first and second rolls; a
mold belt defining an array of cavities extending from an outer
surface of the belt in at least three rows, the mold belt trained
about both the first and second rolls; a source of molten plastic
resin arranged to deliver resin to the outer surface of the mold
belt; means for cooling the resin in the cavities of the belt to
solidify the resin while on the belt; and means for stripping the
cooled resin from the belt, the fastener elements pulled complete
from the belt cavities. The apparatus is constructed to force the
plastic resin into the cavities of the belt under pressure to fill
the cavities as the continuous base of the product is formed on the
outer surface of the mold belt.
[0089] Various embodiments of this aspect of the invention contain
one or more of the features of above-described embodiments of other
aspects of the invention.
[0090] In some embodiments, the source of molten plastic resin
includes a pressurized extruder.
[0091] In some configurations, the extruder is arranged to extrude
the resin into the cavities of the mold belt in a gap defined
between the first roll and the extruder.
[0092] In some other configurations, the extruder is arranged to
extrude the resin into the cavities of the mold belt in a gap
defined between the extruder and a pressure reaction plate disposed
between the first and second rolls.
[0093] In some embodiments, the cooling means comprises a fan
arranged to force air across the mold belt.
[0094] In some embodiments, the cooling means includes coolant
circulated through at least one roll about which the mold belt is
trained.
[0095] In some cases, the cavities of the mold belt are shaped to
form fastener elements having overhanging heads.
[0096] In some other cases, the cavities of the mold belt are
shaped to form fastener element stems. The first roll defines an
array of cavities at its peripheral surface shaped to form fastener
element heads, and has a series of pins extending from its
peripheral surface to engage corresponding holes in the mold belt
for timing the belt with respect to the first roll to align the
cavities of the mold belt with the cavities of the mold roll to
form an array of contiguous fastener element-shaped cavities. The
molten plastic resin fills the array of contiguous cavities at the
first roll to form the array of fastener elements.
[0097] The invention represents a significant improvement over
conventional roll-forming machines and techniques, in many
respects. By removing the mold cavities from the circumference of a
single roll, the cavities can be advantageously circulated through
cooling processes. The forming fastener elements are also afforded
longer residence times, decreasing the rate at which they must be
cooled and enabling greater crystallization during solidification.
This can enable, in turn, lower cavity filling pressures even at
relatively high production rates. In addition, the invention
enables the use of solid rolls which more robustly resist bending
loads than multi-plate rolls. The mold belt can be readily removed
from the molding apparatus for cleaning and replacement, and is
useful for forming, in one simple molding step, complete fastener
products having a wide array of fastener elements all extending
from a single, continuous, strip-form base. Many of the belt
structures featured in the invention are inexpensive enough to
produce that they may be considered disposable if their cavities
become plugged.
[0098] These and other advantages and features will be understood
from the following description, drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0099] FIGS. 1-7 illustrate several different mold belt routings
and machine configurations for molding continuous fastener products
on a mold belt, each routing having different advantageous
features.
[0100] FIGS. 8-16 and 19 illustrate several different mold belt
constructions and cavity shapes useful in the machine
configurations of FIGS. 1-7. FIGS. 8-11, 13-16 and 19 are portions
of transverse belt cross-sections, while FIG. 12 is a portion of a
longitudinal cross-section of the belt of FIG. 11.
[0101] Of the cavity shapes illustrated, those of FIGS. 8-12 and 15
form hook-type fastener elements and those of FIGS. 13, 13A, 14, 16
and 19 form mushroom-type fastener elements.
[0102] FIGS. 17 and 18 are alternate bottom views of the mold
cavity shown in FIG. 16.
[0103] FIG. 20 shows the mold belt of FIG. 19 during molding, with
resin filling a typical mold cavity.
[0104] FIG. 21 is a perspective view of the lower portion of a mold
for molding a section of a mold belt.
[0105] FIGS. 22 and 23 are longitudinal cross-sectional views of
the mold portion of FIG. 21, assembled with other mold components
to form a mold, ready to mold first and second sections,
respectively, of a mold belt.
[0106] FIG. 24 is a longitudinal cross-sectional view of a mold for
molding a section of a mold belt about one or more reinforcement
cables.
[0107] FIG. 25 illustrates a machine configuration for molding
fastener elements using a timed mold belt with through holes
aligned with dimples on a mold roll, for molding fastener element
stems in the belt holes while forming overhanging heads in the roll
dimples, while punching the molded elements out of the belt with
timed projections on a knock-out roll.
[0108] FIG. 26 is a perspective view of a strip-form fastener
product having a two-dimensional array of integrally molded hooks
extending from a common base.
[0109] FIG. 27 is a cross-sectional view of a mold belt timed to a
roll with projections extending into cavities of the belt, for
forming fastener elements with hollow heads.
[0110] FIG. 28 is a partial perspective view of a mold belt formed
of parallel mold plates interconnected with an elastomeric
material.
[0111] FIG. 29 shows the belt of FIG. 28 curved about a roll.
[0112] FIG. 30 is a cross-sectional view through one of the mold
plates of the belt of FIG. 28.
DESCRIPTION OF EMBODIMENTS
[0113] Each of the embodiments shown in FIGS. 1-7 have a
recirculating mold belt 10 for continuously molding fastener
products 12. The belts and rollers are not drawn to scale, and the
thickness of the belt has been exaggerated for purposes of
illustration.
[0114] In each of the illustrated arrangements, the product 12
formed is a sheet-form touch fastener product having a continuous,
broad base of resin from which an entire two-dimensional array of
miniature fastener elements extend, as shown in FIG. 26. The resin
base of the fastener product, typically only about 0.002 to 0.020
inches thick and anywhere from one to 12 inches or more in width,
is formed on one broad surface of belt 10 while the fastener
elements are molded in individual mold cavities extending into the
belt from the surface on which the base is formed. The arrangement
and density of the cavities will vary between embodiments, but it
is generally the case that there will be between 50 and 2500
cavities per square inch of belt surface, generating an array of
fastener elements of a corresponding size and density, with the
fastener elements distributed more or less evenly across the width
of the product in several rows. Although only 6 parallel rows are
illustrated, hundreds or even thousands of rows are formed in some
cases. The fastener elements are either of the hook type, having a
preferably re-entrant crooked tip extending in a single direction
from a stem (or, alternatively, two tips extending in opposite
directions), or the mushroom type, having a head extending in
multiple directions (in many cases, in all lateral directions) from
a stem. The fastener elements so formed are useful for releasably
engaging either fibers or other male fastener elements to form
releasable fastenings. The hook-type fastener elements retain
engaged fibers in their crooks, while the mushroom-type fastener
elements snag fibers on the underside of their heads, as is known
in the art. Cavities for forming hook-type fastener elements are
arranged, in some embodiments, to extend along the longitudinal
direction of the product, for forming what are called "machine
direction" hooks for applications requiring high peel and shear
strengths in a longitudinal direction. In some other embodiments,
hook-shaped cavities are arranged to extend (or "point") across the
width of the belt, for forming what are called "cross-machine
direction" hooks, such as for applications in which the product is
to be loaded in a direction transverse to its longitudinal axis.
Combinations of machine direction and cross-machine direction hooks
are also envisioned, as are hooks extending at various angles to
the machine direction.
[0115] Referring to FIG. 1, an extruder 14 supplies a continuous
stream of molten resin 16 under pressure to a broad surface of belt
10, which is supported against the extrusion pressure by a rigid
plate 18. The distal end of the extruder is configured to form, on
its downstream side, a fixed gap with the belt, such that a layer
of resin of predetermined thickness is formed on the belt at the
extruder. The remainder of the supplied resin is forced into
cavities defined within the thickness of the belt, where it
conforms to the shape of the cavities and solidifies to form the
fastener elements. Thus, the base and fastener elements are formed
simultaneously, integrally molded from the same flow of resin, the
fastener product thereby being formed complete in a single
continuous process. Belt 10 is trained about two driven rolls 20a
and 20b which rotate the belt at a relatively constant and
controlled speed, ranging anywhere from 25 to 150 lineal feet per
minute, corresponding to the production rate of the fastener
product. Downstream of extruder 14, belt 10 carries the solidifying
resin away from the extruder until it is cooled sufficiently to
enable the fastener elements to be stripped from their cavities. As
the required residence time for proper cooling will depend upon
several factors, including resin chemistry, extrusion temperature,
belt structure and temperature, and fastener element geometry, the
location of the optimum stripping point along the belt path will
depend on these variables and belt speed. At relatively low belt
speeds, or when molding smaller fastener elements, the product may
be stripped out at point "A". As production speeds increase, the
optimum stripping point will move to point "B" and perhaps even to
point "C". The extendible length of the belt, as compared to the
fixed circumference of standard mold rolls, enables quite long
residence times at even relatively high production speeds.
Furthermore, the location of the stripping point can be adjusted,
even during production, to optimize the residence time as a
function of any number of control parameters. The empty belt,
stripped of the product, returns to extruder 14 for refilling.
[0116] A forced air cooling system 22 blows directly against the
non-product surface of belt 10, enhancing the heat transfer from
the belt and quickening the solidification of the resin.
Alternately, the cooling system can be arranged to blow against the
back surface of the cooling product. Further cooling is provided,
as needed, by rolls 20a and 20b, for instance by circulating
coolant through the rolls. For even more rapid quenching, the belt
and carried product can be routed through a coolant bath (not
shown).
[0117] By enabling longer residence times, even at high production
speeds, belt molding allows the product to be cooled at a slower
rate than on conventional mold rolls. Slower cooling can enhance
crystallization of resin of the fastener elements, resulting in
advantageous material properties. This can be particularly
important at the surfaces of the fastener elements, where rapid
quenching of the resin as chilled mold roll cavities are filling
can form a skin layer which, besides increasing the pressure
required to completely fill the cavities, tends to have less
desirable properties when cooled than resin at the core of the
fastener elements which is generally allowed to solidify more
slowly. In some applications, pressure block 18 is heated to help
to preheat belt 10 before introducing the molten resin.
[0118] Referring to FIG. 2, extruder 24 is arranged to extrude
molten resin into belt 10 against roll 20a, eliminating the need
for a separate pressure plate. To help balance the pressure load
applied to roll 20a by the extruder, a balance roll 26 transfers
load between rolls 20a and 20b, helping to reduce bending
deflections of roll 20a that would result in product base thickness
variations.
[0119] FIG. 3 shows that the molten resin need not be supplied
under pressure. In this case, the molten resin is introduced to
belt 10 at atmospheric pressure, laid against the surface of the
belt. Subsequently, both belt and resin enter a pressure nip
defined between a pair of rolls 28 which create sufficient pressure
to force some of the resin into the belt cavities to form the
fastener elements, leaving a layer 30 of predetermined thickness on
the surface of the belt to solidify to form the product base.
[0120] FIG. 4 illustrates a more complex belt routing through a
four roll stack similar in arrangement to the roll stack currently
employed in commercial embodiments of Fischer's roll-forming
method. Fischer's multi-plate mold roll is replaced with a solid
roll 32, and belt 10 is routed through all three nips defined by
the four roll stack. The belt is also trained about a pair of
spaced apart idler rolls 34, such that the belt can be
appropriately cooled before re-entering the pressure nip between
rolls 32 and 36. The resin 16 is introduced to the belt at the
pressure nip 38, where pressure between rolls 32 and 36 cause the
cavities to be filled. The belt continues about rolls 32 and 40, at
least one of which is preferably chilled. Neither nip adjacent roll
40 applies any further pressure to the resin, although the surface
of roll 42 may be configured to emboss the back surface of the
product base with any desired pattern or indicia, while the
fastener elements are protected from damage within the cavities of
the belt. Optionally, a backing 44 (such as a fabric with
engageable fibers) may be laminated to the back surface of the
resin product base between rolls 40 and 42, as shown. While the
product is carried about roll 40, its back surface can be treated
(e.g., by heat or the application of an adhesive) to prepare it for
receiving the backing. The belt continues to carry the cooling
product, with the fastener elements disposed within its cavities,
until the product 12 is stripped from the belt at one of the idler
rolls 34.
[0121] The arrangement of FIG. 5 dispenses with any idler rolls,
belt 10 being trained about driven rolls 36 and 46. Tension in the
belt produces a normal load between the outer surface of the belt
(the surface from which the cavities extend in the case of cavities
not extending through the thickness of the belt) and roll 32. As in
the embodiment of FIG. 4, resin is forced into the fastener element
cavities of the belt by nip pressure between rolls 32 and 36. In
this arrangement, roll 32 must generally be cooled sufficiently to
solidify the resin while still against roll 32, as the fastener
elements are stripped from their cavities relatively soon. Two
variations of product routing are shown.
[0122] In FIG. 6, belt 10 is trained about driven roll 32 and a
spaced apart, auxiliary roll 48 adjacent a belt cooling system 22.
Again, the overall length of the mold belt is much greater than the
circumference of driven roll 32, increasing the time between resin
filling cycles for individual belt cavities 52. Thus, the belt can
be adequately cooled before returning to the pressure nip 38.
[0123] FIG. 7 illustrates a belt routing for use with a four roll
stack, in which the belt is introduced to pressure nip 38 adjacent
roll 32. The belt may be routed about upper roll 42, or proceed
directly from roll 40 to upper idler roll 34, as shown. A loop
fabric material 44 is introduced to the pressure nip along with the
belt and resin, being thereby laminated to the back surface of the
resin base of the product as the base is formed. Other details
regarding effective nip lamination of sheet form materials to the
back surfaces of fastener products may be found in Kennedy et al.
U.S. Pat. No. 5,260,015, the teachings of which are hereby
incorporated by reference. Acceptable loop materials include the
non-woven loop product disclosed in U.S. Ser. No. 08/922,292, filed
Sep. 3, 1997 and incorporated herein by reference.
[0124] The fact that the curvature of mold belt 10 changes while
the cooling resin is carried by the belt can provide advantages in
some instances. In FIG. 4, for example, the thickness of the resin
base of the product is initially determined by the width of the gap
between rolls 32 and 36, at which point the mold belt is locally
flat (having no curvature). Immediately upon leaving nip 38,
however, the belt assumes the curvature of roll 32. The curvature
is reversed about roll 40. Depending on the ratio of the belt
thickness to the radius of roll 40, the amount of longitudinal
strain applied to the outer surface of the mold belt may be
significant, increasing the relative spacing of the fastener
element cavities and effectively stretching the cooling product
base in the process. This can result, in some situations, in a
thinner product base. Where this effect is undesirable, the radius
of any curvature followed by the mold belt while carrying the
product should be sufficiently large (with respect to the belt
thickness). For instance, training a 0.125 inch thick belt about a
roll of about 12 inches diameter causes negligible base strain.
[0125] Strain in the surface of the curved belt can also be
employed to help fill the fastener element cavities. For example,
consider the effect of the belt curvature in the configuration of
FIG. 7. In pressure nip 38, where the molten resin is introduced to
belt 10, the base-forming surface of the belt is under heightened
tension (as compared to the nominal belt tension) due to the fact
that the belt is locally forced to follow the curvature of roll 32
(which it maintains about approximately half the circumference of
roll 32). In this condition, the openings of the cavities at the
base-forming surface of the belt are slightly distended (i.e.,
stretched open). As the belt proceeds about roll 40, the curvature
(and its corresponding effect on the cavity openings) is reversed,
laterally compressing the resin resident within the cavity
openings. This curvature reversal therefore can result in a
supplemental resin pressure that can help to force the cooling
resin up to the distal ends of the cavities. In the gap between
rolls 40 and 42, its curvature subsides and the cavity openings
return briefly to a non-stressed condition, opening slightly from
their condition about roll 40 and thereby separating from the sides
of the cooled fastener elements in anticipation of their removal as
the belt continues on around roll 42. Thus, the changing curvature
of the mold belt can be used to advantage to help form and strip
the molded fastener elements in ways unavailable in fixed-curvature
roll molding.
[0126] Belts 10 for use in any of the foregoing machine
configurations may have any of the following characteristics.
[0127] In FIG. 8, the cavities 52 in mold belt 10 are formed by
multiple layers of plating 54 applied in successive steps to a
belt-form workpiece 56. The material of workpiece 56 and plating 54
are preferably selected to have about the same stiffness for
surviving the small amount of flexure that occurs as the belt
revolves about the rolls. Useful workpiece materials include 301
stainless steel, for instance. As described in U.S. Ser. No.
08/920,188, a photoresist material is applied to the surface of the
workpiece to mask areas not to be plated. The thickness of each
plating layer is controlled to be about the same as the thickness
of the associated masking layer of photoresist material. In
successive stages, alternating steps of applying photoresist
material and plating the workpiece progressively form fastener
element-shaped cavities 52, with the last plating layer forming the
outer surface 58 of the finished mold belt.
[0128] The mold belt illustrated in FIG. 9 consists entirely of
flexible thermoset resin 60, such as an RTV silicone or urethane,
which is molded about existing, hook-type fastener elements. After
the thermoset resin has cured, the fastener elements are stripped
from the thermoset resin, leaving fastener element-shaped cavities
52 defined entirely by the resin of the belt. One method of molding
such a belt in longitudinal sections is described below with
respect to FIGS. 21-23. Resin 60 should be selected to be
sufficiently flexible to withstand the cyclic bending loads applied
to the belt, while being rigid enough (i.e., having a sufficiently
high durometer) to withstand the molding pressures needed to fill
the belt cavities. The molding pressures typically need not be as
high as in conventional roll-molding methods (such as taught by
Fischer) because the cavity surfaces need not be as cold when
receiving the molten resin, and the molten resin itself may have a
lower viscosity as applied to the cavities. The lower thermal
conductivity of the thermoset resin (as compared to the metal of
conventional roll mold plates) helps to keep the filling resin at
an elevated temperature during the filling process, allowing more
crystallization of the molded resin before it solidifies.
[0129] The cavities 52 of the mold belt of FIG. 10 are defined by a
layer of molded thermoset material 60, as in FIG. 9, but the belt
also includes a layer of metal 62 adjacent the enclosed heads of
the fastener element cavities. The metal layer enhances the
stiffness and strength of the belt, enabling higher belt tensions,
and can enhance heat transfer from the resin cooling in the belt
cavities.
[0130] FIGS. 11 and 12 illustrate a belt 10 of reinforced resin.
The belt is of thermoset resin 60 molded about hook-type fastener
elements and containing metal reinforcement elements running the
length of the mold belt. The left of FIG. 11 shows one form of such
reinforcement elements, a braided metal cable 64 running in between
fastener element cavities. Shown in the middle of FIG. 11 are
individual reinforcement wires 66, one of which (wire 66a) is
disposed within the crook portion of some of the fastener element
cavities. The outline of wire 66a is shown in FIG. 12, extending
through the crook portions of multiple mold cavities. To the right
of FIG. 11, a longitudinal metal band 68 is shown, extending
between the fastener element cavities and running the length of the
mold belt. Whatever the form of the reinforcement elements, whether
bands, strips, wires or cables, their function is to enhance the
strength of the mold belt. Preferably, they are also arranged to
enhance the thermal conductivity of the belt. For instance, metal
band 68 is exposed on the back surface of the belt where it may be
placed in contact with chilled surfaces along the routing of the
belt to accelerate belt cooling.
[0131] FIG. 13 illustrates a mold belt structure for forming
mushroom-type fastener elements integrally with a sheet-form base.
Belt 10 is a continuous loop of 0.015 inch thick 301 stainless
steel defining an array of 0.015 inch diameter holes 52 through its
thickness. Given its thickness and material, belt 10 has a minimum
practical bend radius of about 10 inches. Other useful belt
materials include other stainless steels, PTFE, beryllium copper,
and urethanes. While holes 52 may be formed by any number of
methods, a useful flare at each hole opening is readily formed when
photochemical etching techniques are employed on an etchable metal
belt. To etch the holes through the belt, a photoresist mask is
applied to both belt surfaces and the belt is etched through holes
in the mask. The mask holes on each side of the belt are aligned,
such that etchant applied to each side of the belt will etch away
belt material to form through-holes. The flared openings on the
side of the belt where the product base is formed help to form
fillets about the fastener element stems. The flared openings on
the side opposite the base are filled with resin that, when
stripped from the belt, forms a very thin head at the distal end of
each stem. Although the diameter of such a head is not much more
than the diameter of its integrally molded stem, even the small
amount of overhang is sufficient to snag some loops. Low-lying
loops, such as are found in non-wovens, for example, are
particularly well snagged by the very thin heads formed by the mold
belt of FIG. 13.
[0132] FIG. 13A shows a belt 10 consisting of stainless steel
insert grommets 130 embedded in a belt-form substrate of flexible
resin 132. Each grommet has a stamped cavity 134 extending through
it, with an enlarged region for molding a head overhanging a
central stem. A flange 136 is provided around each circular grommet
130 to help to secure it within the surrounding resin. This belt is
formed by placing the grommets as inserts within a mold and
injecting the resin about them.
[0133] Using a mold belt with cavities extending through its
thickness (such as shown in FIGS. 13-19) involves somewhat
different considerations than molding fastener elements in blind
cavities (as are shown in FIGS. 8-12). During filling, the distal
end of each cavity must be closed by another surface, for instance.
In the machine configuration of FIG. 1, this function is provided
by pressure plate 18. In FIGS. 2 and 3, the surface of roll 20a and
roll 28, respectively, closes off each fastener element cavity as
it is filled, forming the outer surface of each fastener element
head. In FIGS. 4 and 5, pressure roll 36 locally blocks flow
through the outer cavity openings, and roll 32 does so in FIGS. 6
and 7.
[0134] FIG. 14 shows a countersunk hole 52 machined through belt 10
by standard drilling techniques. The nominal hole diameter is about
0.006 inch, and the 90 degree countersink extends the diameter of
the hole at its outer opening to about 0.015 inch. To help remove
the enlarged heads molded in such cavities without pulling them
from their stems, the heads can be punched from their cavities with
appropriate protrusions extending from the surface of a stripping
roll, the protrusions timed to align with the belt cavities. Such a
timed arrangement is shown in FIG. 25, for instance, in which mold
belt 10 defines an array of through holes 52 as shown in FIG. 13,
and a series of timing holes that are engaged by pins 70 extending
from mold roll 72 and upper roll 74 to coordinate the position of
the belt cavities with both head-forming cavities 75 in the surface
of roll 72 and head-releasing protrusions 76 of roll 74. This
arrangement forms fastener elements with bulbous heads 78 (shaped
by the dimples 75 of roll 72) extending from cylindrical stems
(formed in the belt cavities). To push heads 78 through the smaller
belt cavities, the heads are each engaged by a corresponding
protrusion 76 of roll 74, thus helping to remove the fastener
elements complete from belt 10 without separating the heads from
their stems. The belt may be formed as a continuous loop, as shown,
or may be in the form of a disposable strip which is removed from
about the molded fastener elements by a suitable chemical or
mechanical process (e.g., by dissolving the strip or by tearing it
off of the fastener product). Similarly, if belt 10 has countersunk
fastener cavities as shown in FIG. 14, suitable heads may be formed
without any dimples 75 formed in roll 72 (and therefore without any
need for timing pins 70 on roll 72), the protrusions 76 of roll 74
serving to push the heads formed within the countersunk regions of
the belt cavities out of the belt.
[0135] As shown in FIG. 27, in another embodiment a belt with
enlarged-head fastener element cavities is trained about a roll 137
having protrusions 138 extending radially from its outer surface.
Belt 10 is timed to roll 137 to align its fastener element cavities
with the protrusions 138 of the roll, whereby a recess is formed by
the protrusions in the distal end of each of the fastener elements
molded in the belt cavities. Such recesses can reduce the stresses
applied to the fastener element heads as they are pulled (or
pushed) from their cavities, the recesses providing space for the
temporary deflection of the head as it traverses the narrower
region of the cavity adjacent the base of the product. The holes
140 shown in roll 137 are for the circulation of coolant to cool
the belt and carried resin.
[0136] As illustrated in FIG. 15, photochemical etching techniques
are also employed to create hook-type fastener element cavities 52
through the thickness of a mold belt 10. To form the stem portion
of such a cavity, etchant is applied to a masked surface
corresponding to the base-forming surface of the belt, etching away
belt material to form the stem portion 80 of the cavity, extending
through at least most (if not all) of the thickness of the belt.
Subsequently, etchant is applied to the opposite surface (through a
suitable mask) to form the overhanging crook portion 82 of each
cavity. The result is a cavity shaped to form a hook-type fastener
element having a relatively flat upper surface. The flare about the
head-forming opening of the cavity creates a thin lip about the
perimeter of the fastener element head, which helps to snag
low-lying fibers.
[0137] FIG. 16 shows an etched fastener element cavity which has
been selectively etched from both sides to form an extended
head-forming cavity 84 of significantly larger overall diameter
than the nominal diameter of a contiguous stem-forming cavity 86.
As shown in FIGS. 17 and 18, examples of the overall shape of
head-forming cavity 84 include simple circles (FIG. 17) and
multi-petal configurations (FIG. 18). In either case, the shape and
overall depth of the head-forming cavity is determined by
controlling the etching process and mask aperture shape.
[0138] FIG. 19 shows a cylindrical cavity 52 extending through the
thickness of a belt 10 which is in the form of a laminate
consisting of a metal layer 88 and an elastomeric layer 90. While
the metal is sufficiently rigid to withstand cavity-filling
pressures without distortion, the durometer of elastomeric layer 90
is sufficiently low that cavity filling pressures laterally
compress the elastomeric material, locally increasing the size of
the fastener element cavity under pressure to form an overhanging
head. For instance, FIG. 20 shows the cavity under pressure and the
resulting deformation of elastomeric layer 90. Sufficiently
elevated filling pressures can, in some circumstances, slightly
lift the belt from the adjacent cavity-stopping surface 92, causing
the resin to extend radially a short distance between belt 10 and
surface 92, further increasing the overall diameter of the molded
heads of the fastener elements.
[0139] FIG. 21 shows part of a mold 94 for molding belts about
hook-type fastener elements (such as the belt of FIG. 9, for
instance). In this illustrative belt-forming process, strips of
plastic fastener product 96 are affixed to the lower surface of a
belt molding cavity 98 with their arrays of fastener elements
extending upward into the cavity. As shown in FIG. 22, mold 94 is
assembled with an upper plate 100 and an end cavity plug 102 to
form an enclosed, elongated cavity 104 for forming a discrete
length of mold belt. In some embodiments, multiple strips of
fastener product 96, each having hook-type fastener elements
arranged to face along their length (i.e., having machine direction
hooks) are arranged side-by-side across the floor of cavity 104,
such that their hooks face in the cross-machine direction with
respect to the length of the cavity (and the length of the
as-formed belt). Cavity 104 is evacuated through a vacuum port 106
and then filled with uncured thermoset resin through a fill port
108. An appropriate seal 110 is provided about cavity plug 102,
which is held in place by a pin 112 extending from upper plate 100.
Plug 102 has a flange 114 which extends into cavity 104 adjacent
upper plate 100, mirroring an extension 116 of the mold cavity at
the other end of the mold. A pin 118 extends into the mold cavity
from the upper plate to form a hole in each belt section which is
later used to locate the molded belt section to the mold while an
adjacent section is molded. After the first belt section is molded,
the mold assembly is opened and the belt section is stripped from
the fastener elements of product strips 96.
[0140] The end cavity plug of the mold assembly is then replaced
with the first molded belt section 120 (FIG. 23), held in place by
pin 112 and sealed by seal 110, and a second belt section is molded
directly on one end of the first section. This process is repeated
until the belt is of a desired length, at which point the two free
ends of the belt may be joined by bonding their overlapping
flanges.
[0141] FIG. 24 shows a belt section mold 122 configured for molding
belt sections on one or more continuous loops of reinforcing cable
64 (e.g., for forming the reinforced belt of FIG. 11). To
accommodate the cable, about which the belt section is to be
formed, the end cavity plugs 124 and 126 are each in the form of
two interlocking plates defining therebetween sealed channels for
receiving and retaining the parallel cables 64. After the first
belt section is molded, it replaces cavity plug 124, and the second
belt section is formed. This process is repeated until only one
length of belt is yet to be formed about cables 64 to make a
continuous belt. For the last molding step, cavity plug 126 is also
removed, and the last belt section is molded directly between the
two free ends of the pre-molded belt sections.
[0142] Metal belts, such as the stainless steel belt shown in FIG.
13, may be formed from strip stock by joining the two ends of a
strip, for example, by electron beam welding.
[0143] Another belt construction is illustrated in FIGS. 28-30.
Referring first to FIG. 28, belt 142 is formed of a series of thin
metal mold plates 144, spaced apart and interconnected with
elastomeric material 146, such as a heat-resistant rubber, RTV,
silicone or urethane compound. Material 146 forms flexible layers
separating the rigid mold plates and providing flexibility in the
overall belt, and may include a metal powder for enhanced heat
conductivity. Each mold plate 144 has a series of mold cavities 148
formed along one longitudinal edge at the outer surface of the
belt, for receiving molten resin and forming the array of fastener
elements. Cavities 148 may be cut through the thickness of each
plate, as shown, in the profile of a hook-type fastener element, or
may be etched into one of the broad surfaces of each plate along a
longitudinal edge.
[0144] As belt 142 is curved about a roll, as is shown in FIG. 29,
the elastomeric material at the outer surface of the belt
stretches, and the elastomeric material at the inner surface of the
belt compresses, as the belt flexes. During flexing, each of the
rigid mold plates 144 remains essentially in a radial orientation,
the gap between adjacent plates being larger at the outer surface
of the belt than at its inner surface. During such flexing, small
depressions may form between the mold plates at the outer surface
of the belt. By applying molten resin to the mold belt in such a
flexed condition, the interplate depressions can advantageously
form shallow transverse ribs in the surface of the fastener
product, running between adjacent transverse rows of fastener
elements. The curvature shown in FIG. 29 is exaggerated for
purposes of illustration.
[0145] Preferably, the mold plates of the mold belt each have a
thickness of less than about 0.020 inch, a length of at least about
0.5 inch, and a width, corresponding to mold belt thickness, of
between about 0.040 and 0.25 inch. The mold plates are spaced apart
to define interplate gaps, filled with the elastomeric material, of
between about 0.005 and 0.025 inch.
[0146] To enhance the attachment of mold plates 144 to the
elastomeric material 146, a series of holes 150 are provided
through each mold plate, as shown in FIG. 30. The elastomeric
material fills the holes as the belt is formed, connecting the
solidified resin on either side of each mold plate. To add
longitudinal strength to the belt, metal reinforcement cables 152
are strung through holes 150 before the elastomeric material is
cast about them.
[0147] Belt 142 is formed by filling cavities 148 of the individual
mold plates 144 with a removable filler material, such as wax,
stringing the mold plates on reinforcement cables 152, spacing the
mold plates out within a strip-form mold cavity, and injecting the
elastomeric material into the spaces between the plates. After the
elastomeric material has solidified, the filler material is removed
from the fastener element cavities. The elastomeric material is
readily formed one section of the belt at a time, in a mold cavity
similar to the one shown in FIG. 24.
[0148] The above embodiments are for example only, and are not
intended to limit the scope of the invention. Other embodiments and
features will be apparent upon closer examination of the drawing,
and even more embodiments will be understood by those of ordinary
skill upon further reflection, and are intended to be within the
scope of the following claims.
* * * * *