U.S. patent application number 10/732614 was filed with the patent office on 2004-06-24 for strip-form fastening and dispensing.
This patent application is currently assigned to Velcro Industries B.V., a Netherlands Antilles Corporation. Invention is credited to Erickson, Paul R., Shepard, William H..
Application Number | 20040121694 10/732614 |
Document ID | / |
Family ID | 22461264 |
Filed Date | 2004-06-24 |
United States Patent
Application |
20040121694 |
Kind Code |
A1 |
Shepard, William H. ; et
al. |
June 24, 2004 |
Strip-form fastening and dispensing
Abstract
A dispenser for strip materials, e.g. hook and loop fastener
material, which automatically finds formations in a continuous
fastener strip during its dispensing and, at that point in the
dispensing procedure, produces a resistance to the remaining
supply, that enables parting of the lead unit from the remaining
supply, thus dispensing a discrete unit. The dispenser has a
receptacle to hold the supply of fastener strip material; it
employs a retarding device to provide light drag against the motion
of the strip as the leading strip unit moves from the dispenser in
response to pull by a user. A detent downstream of the retarding
device engages a corresponding formation in the strip material to
resist movement of the remaining strip material, so that the strip
ruptures along a line of weakness under a user's tension. Also
disclosed are dispensable fastener strips of various forms, some
advantageously formed by use of needled bat, and methods of forming
the fastening strips.
Inventors: |
Shepard, William H.;
(Amherst, NH) ; Erickson, Paul R.; (New Boston,
NH) |
Correspondence
Address: |
FISH & RICHARDSON PC
225 FRANKLIN ST
BOSTON
MA
02110
US
|
Assignee: |
Velcro Industries B.V., a
Netherlands Antilles Corporation
|
Family ID: |
22461264 |
Appl. No.: |
10/732614 |
Filed: |
December 9, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10732614 |
Dec 9, 2003 |
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09863003 |
May 22, 2001 |
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6660202 |
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09863003 |
May 22, 2001 |
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09133991 |
Aug 14, 1998 |
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6235369 |
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Current U.S.
Class: |
442/402 ;
442/327; 442/381 |
Current CPC
Class: |
A44B 18/0069 20130101;
A44B 18/0011 20130101; Y10T 225/20 20150401; Y10T 225/30 20150401;
Y10T 428/24008 20150115; Y10T 428/1476 20150115; Y10T 225/21
20150401; D04H 11/00 20130101; Y10T 442/659 20150401; B65H 35/002
20130101; A44B 18/0003 20130101; Y10T 24/2708 20150115; Y10T 428/15
20150115; Y10T 428/14 20150115; Y10S 428/906 20130101; Y10T 225/205
20150401; Y10T 442/682 20150401; A44B 18/0084 20130101; Y10T
428/1486 20150115; B65H 35/10 20130101; A61F 13/62 20130101; Y10T
428/24017 20150115; Y10T 442/60 20150401; Y10T 225/23 20150401 |
Class at
Publication: |
442/402 ;
442/327; 442/381 |
International
Class: |
D04H 001/46; D04H
001/00; B32B 005/26 |
Claims
What is claimed is:
1. A sheet-form material having first and second sides that carry
respective fastener elements, fastener elements on at least the
first side comprising a non-woven web of entangled fibers of
substantial tenacity having a basis weight of between 1.8 to 2.5
ounces per square yard.
2. The material of claim 1 wherein the non-woven web comprises a
batt of loose, stable fibers that have been entangled and form a
non-woven web structure of fibers joined at entanglements, loops of
some of the fibers extending from at least one side of the web.
3. The material of claim 2 wherein the non-woven structure is
bonded in a stretched state in which tightened entanglements form
knots.
4. The material of claim 3 wherein the knots are bonded in a
stretched state by resin integral with the material that forms the
fastening elements on the second side of said strip material.
5. The material of claim 2 wherein the batt is of needle punched
form.
6. The material of claim 1, wherein the fastener elements on the
second side of the material comprise hooks molded integrally with a
base layer.
7. The material of claim 6 wherein the web of entangled fibers is
bonded to the base layer of the hooks by material of the base
layer.
8. The material of claim 1 having weakened parting lines at spaced
intervals along its length to define individual strip units.
9. The material of claim 8 further comprising at least one
engagement formation within each strip unit, the engagement
formation constructed and arranged to be engaged by a detent to
detain the respective unit while a preceding unit is detached by
rupture at the parting line by tension applied to the parting
line.
10. An extended length of fastener material forming a series of
detachable strip units, said fastener material having a strip-form
base defining therein weakened parting lines at spaced intervals
along its length to define the strip units therebetween; and a
non-woven web of entangled fibers of substantial tenacity having a
basis weight of between 1.8 to 2.5 ounces per square yard and
forming an array of engageable loops across a broad side of the
base.
11. The fastener material of claim 10 further comprising an array
of male fastener elements extending from the base and arranged to
releasably engage the loops.
12. The fastener material of claim 11 wherein the male fastener
elements comprise hooks.
13. The fastener material of claim 11 wherein the fastener elements
are integrally molded with resin of the strip-form base.
14. The fastener material of claim 10 wherein each strip unit
includes one engagement formation constructed and arranged to be
engaged by a detent to detain the respective unit while a preceding
unit is detached by rupture at the parting line by tension applied
to the parting line.
15. The fastener material of claim 10 wherein the non-woven web
comprises a batt of loose, stable fibers that have been entangled
and form a non-woven web structure of fibers joined at
entanglements, loops of some of the fibers extending from at least
one side of the web.
16. The fastener material of claim 15 wherein the non-woven
structure is bonded in a stretched state in which tightened
entanglements form knots.
17. The fastener material of claim 16 wherein the knots are bonded
in a stretched state by resin integral with the material that forms
the fastening elements on the second side of said strip
material.
18. The fastener material of claim 15 wherein the batt is of needle
punched form.
19. The fastener material of claim 10 wherein the web of entangled
fibers is bonded to the base by material of the base.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. Ser. No.
09/863,003, filed on May 22, 2001, which is a divisional of U.S.
Ser. No. 09/133,991, filed on Aug. 14, 1998, now U.S. Pat. No.
6,235,369.
TECHNICAL FIELD
[0002] This invention relates to dispensing fasteners and other
items made in continuous strip form and to fastener strips suitable
for dispensing.
BACKGROUND
[0003] The invention in one aspect concerns an overall system
including a dispenser and a cooperating continuous strip of
fastener units that leads to lower cost and wider applicability of
fastening by the hook and loop technique.
[0004] Elongated strips of hook and loop fasteners are used as
straps or ties for bundling and wrapping products, for applying
identification markings to products, etc.
[0005] Previously, a continuous strip of fastener units has been
provided with cross-perforations or lines of weakness spaced at
predetermined interval lengths to define the individual units,
which can be detached from one another. In some cases, the strip is
wound upon itself to form a supply roll. The user uncoils a unit
from the roll, finds the line of weakness, and breaks it from the
supply roll by tension. Time can be lost in finding the line of
weakness, and if a mistake is made, two units instead of one may be
detached.
[0006] Other items made in continuous sequence as a continuous
strip, to be detached at lines of weakness, present similar
problems.
SUMMARY
[0007] A dispenser device is provided which automatically finds the
second unit in a continuous strip during dispensing of a leading
unit and, during the dispensing procedure, automatically applies
resistance to the second unit, so that pull on the leading unit
parts it from the remaining supply. The labor saved by
automatically singulating a strip-form unit decreases cost and
increases convenience, especially in the case of touch
fasteners.
[0008] It is also realized that, by providing a dispenser that is
convenient to use, there are potential large volume applications
for strip-form fastener units for marking, bundling, or wrapping a
wide variety of products that include banding or bundling of wires,
fiber optic cables, hydraulic or pneumatic tubes, and many other
products that are typically grouped together for use or for
sale.
[0009] In a preferred form, a supply of strip-form fastener units
is provided as a roll. Dispensing is achieved by the user grasping
the free end of the roll and pulling it across a mechanism which
finds the second unit, locks on to it and applies strong resistance
to its movement, so that, as the user continues to pull, the
leading unit breaks away from the next unit under tensile force. In
a preferred form, the device which senses the strip and resists
movement of the next-succeeding unit automatically releases the
remaining unit when the perforation is broken. In preferred forms,
the next succeeding strip-form unit, which now becomes the leading
unit, is automatically lifted and presented to be grasped for
repeating the procedure.
[0010] In preferred forms, the dispenser also has a mechanism which
continuously applies light drag resistance to the strip material
being pulled from the roll so that pull on the roll does not cause
it to overrun or result in improper action.
[0011] In its preferred form, the device which senses the strip and
resists movement of the next-succeeding unit automatically releases
the remaining unit when the perforation is broken.
[0012] In a preferred form, a formation is provided on each unit of
the strip material and a detent, in preferred form a simple claw,
engages the formation applies the resistance to the second unit so
that tension on the lead unit breaks it away.
[0013] Preferably the sensing and strong resisting action is
performed by a detent over which the strip material slides during
dispensing movement.
[0014] Advantageously, the strip-form units are provided with an
inherent curling tendency or set (curl memory) from having been
wound in a roll, and the supply roll is so arranged in the
dispenser, that this curling characteristic serve to help raise the
end of the lead strip unit, to present it to be grasped.
[0015] The techniques of the invention are applicable to many strip
materials, but in particular, to fastener materials, especially
hook and loop fastener components such as hook strips, loop strips,
strips having hooks on one side and loops on the other, and strips
having pressure sensitive adhesive or other fastening features on
one or both sides.
[0016] An inexpensive fastener material, capable of being dispensed
by this technique, is two-sided material, having fastener hooks on
one side and loop material on the other, formed by in situ molding
and laminating in which the resin that forms at least part of the
base layer of the hooks serves also as the bonding agent for
adhering the needled non woven loop material to the base layer.
[0017] In a particularly effective system, the strip-form fastener
units comprise molded fastener hooks to which is directly bonded a
needled and stretched non-woven material whose loops or fibers are
constructed and arranged to be engaged by the hooks. Advantageously
this product is formed by the in situ molding techniques.
[0018] Another fastener material especially adapted for the
dispensing techniques disclosed is a tape having hooks or loops on
one surface and pressure sensitive adhesive on the other side, the
tape having special formations that enable the dispensing system to
function. In some cases a release liner is employed on the
adhesive. In important other cases, the adhesive is formulated to
releasably engage overlying portions of the tape, so that it can be
supplied rolled or folded upon itself, with no release liner. For
applying drag to such a tape while being withdrawn from the
dispenser, it is advantageous to apply the light drag force by
action of a roller, such as a roller that is spring biased against
the adhesive side of the tape, which turns with the advancing
adhesive, and presses the opposite side of the strip against a
braking (drag) surface.
[0019] According to one particular aspect of the invention, a
dispenser is provided for a supply of continuous strip material,
the material having formations that include parting lines spaced at
points along the length to define successive units of predetermined
length, the parting lines enabling a leading unit to part from the
remaining material when the material at the respective parting line
is subjected to parting tension, the dispenser comprising a
receptacle to hold the supply of strip material, a retarder
constructed and arranged to provide drag against the motion of the
material as a leading unit is removed from the dispenser in
response to pull by a user, and a device, (in certain preferred
embodiments located downstream of the retarder) positioned to be
engaged by the strip material as the leading unit is pulled from
the dispenser, the device comprising at least one detent
constructed to engage a corresponding formation of the second unit
following the leading unit to resist movement of the following unit
so that the leading unit parts from the remaining material at the
respective parting line.
[0020] Preferred embodiments of this aspect of the invention have
one or more of the following features.
[0021] The receptacle of the dispenser is constructed and arranged
to hold a supply of fastener strip material having parting lines
defining strip-form fastener units. The dispenser is combined with
a supply of fastener strip material having fastener elements on at
least one of its sides, preferably the fastener elements comprising
hooks or fibers or loops for hook and loop fastening or fasteners
constructed for self-engageable fastening; in some advantageous
cases, the fastener strip material is two-sided, having hooks on
one side and hook engageable fibers or loops on the other side, and
in some cases, the fastener strip material has hooks or
hook-engageable fibers or loops on one side and pressure-sensitive
adhesive on the other side. In certain cases, a release layer lies
over the pressure sensitive-adhesive and the parting line extends
into the release layer.
[0022] The detent comprises at least one stationary claw over which
the strip material slides as the leading unit is pulled from the
dispenser until a formation of the second unit of strip material
that is engageable by the claw is engaged by the claw.
[0023] The retarder includes a resilient member that bears against
the strip material as the leading unit is withdrawn. Preferably,
the retarder includes a leaf spring, preferably the downstream end
of the leaf spring is positioned and arranged to be resiliently
deflected in response to pull on the leading unit. Preferably, the
downstream end of the spring is curved away from the path of the
strip material.
[0024] In certain advantageous cases, the retarder, e.g. the
resilient member or spring, is constructed and arranged to position
the next-following unit for grasping upon breaking of the leading
unit from the remaining material. In certain cases, the resilient
member is constructed and arranged to raise a portion of the strip
unit immediately following the leading unit breaking from the
remaining material. In some embodiments, the resilient member
comprises an elongated spring member such as a leaf spring exposed
for face-to-face engagement with the under-surface of the strip
material, positioned to raise the end of the next-following unit
when the leading unit is broken away. Preferably, the downstream
end of the spring member is arranged to be resiliently deflected
downwardly by withdrawing tension applied to the leading strip
unit, and, upon relief of the tension as a result of breaking of
the leading unit from the remaining strip material, the spring is
constructed and arranged to move upwardly in restoring motion to
carry with it the strip material that extends beyond the spring
into position to be grasped.
[0025] In a preferred form, a leaf spring member has a main portion
at the retarder and a downstream end portion of the leaf spring
beyond the retarder that is thinner than the thickness of the main
portion of the leaf spring, the downstream end portion arranged to
be resiliently deflected during removal of a leading strip and to
elastically recover upon parting of the leading unit, the spring
carrying with it a corresponding portion of the successive unit.
The retarder includes a spring-loaded roller.
[0026] Hooks are integrally molded on a portion of the exterior of
the dispenser, enabling the dispenser to be releasably mounted on
loop material secured to a support.
[0027] The dispenser is combined with advantage with certain
supplies of strip material. In certain important cases, units of
the material have a slit engageable by the detent, each slit ending
at a stop surface that enables the detent to stop movement of the
second unit. In certain other cases, units of the strip material
have formations at the leading end of each discrete strip unit, or
in its main body, exposing a detainable edge portion of the unit
for engagement by the detent.
[0028] In a preferred embodiment, the fastener material has
sufficient stiffness and roll set (curl memory) to spring from a
bent configuration as it is pulled across the detent to a
straighter or reversely curved shape when the leading unit is
broken from the next succeeding unit so that a portion of the next
unit lifts from the detent in position to be grasped by a user for
dispensing.
[0029] In a preferred form, the dispenser is constructed to hold a
supply of strip material in roll form. In another form, the
dispenser is constructed to hold material folded upon itself in a
Z-fold. In certain embodiments, the dispenser is constructed and
arranged to enable withdrawing a strip unit by one hand of a user.
In certain cases, the dispenser has a base suitable for resting
upon a flat surface and in certain cases it is constructed and
arranged to be portable or hand-held. In some cases, the dispenser
has hooks integrally molded on a portion of its exterior enabling
the dispenser to be releasably mounting on loop material secured to
a support. In certain cases, advantageously, the dispensing section
is angled relative to the surface on which its base is supported,
so that the strip unit can be withdrawn at a convenient angle, e.g.
at an upward angle relative to a horizontal surface on which the
base of the dispenser rests.
[0030] In a preferred form, the dispenser has edge guides for
engagement by edges of the material being withdrawn from the
dispenser to guide the material to be engaged by the detent in the
formations provided in the material.
[0031] In another aspect of the invention, the dispenser is
combined with a supply of fastener strip material having
substantial lateral stiffness, the dispenser including edge guides
in the vicinity of the detent to guide this fastener strip to
ensure the detent engages the respective formation in the strip
material.
[0032] In another aspect the dispenser is combined with a supply of
fastener strip material, the material carrying arrays of fastener
elements on its first and second sides, the respective fastener
elements being of cooperative form capable of being releasably
fastened together. In some cases, advantageously, fastener elements
on the first side comprise loops or fibers of form capable of being
releasably engaged by fastener elements on the second side. In
certain cases, the fastener elements on the second side of the
material are hooks molded integrally with a base layer, the loops
or fibers being bonded to the base layer of the molded hooks by the
material of the base layer.
[0033] In another aspect of the invention, which involves novel
combination with the dispenser described, as well as a new fastener
product per se, the first side of the material comprises a
non-woven web of entangled fibers of substantial tenacity having a
basis weight of between about 1.8 to 2.5 ounces per square yard. In
preferred embodiments, fibers or loops are defined by a non-woven
web which comprises a batt of loose, staple fibers that have been
entangled and form a non-woven web structure of fibers joined at
entanglements, loops of some of the fibers extending from at least
one side of the web; in certain cases, the batt is of needle
punched form. In some cases, the non-woven structure is bonded in a
stretched state in which tightened entanglements form knots. In
certain cases, the knots are bonded in a stretched state by resin
integral with the material that forms the fastening elements on the
second side of the strip material.
[0034] According to another aspect of the invention, an extended
length of fastener material is provided that forms a series of
detachable strip units suitable for use with a dispenser having a
detent, the fastener material having formations that include
weakened parting lines at spaced intervals along its length to
define the strip units and at least one formation in each strip
unit, the formation constructed and arranged to be engaged by the
detent to detain the respective unit while a preceding unit is
detached by rupture at the parting line by tension applied to the
parting line.
[0035] Advantageously, the strip material has sufficient lateral
stiffness to enable it to be guided by edge guides to register the
detent with the formation of each strip unit.
[0036] Preferably, the fastener material has sufficient resiliency
to spring from a bent configuration as it is pulled across a detent
to a straighter shape when the leading unit is broken away from the
remaining material to assist the succeeding unit to lift from the
detent in position to be grasped by a user for dispensing the next
successive strip unit.
[0037] A preferred method for forming a composite product having a
large multiplicity of hook-form fastener projections extending from
the surface of its base portion comprises the following steps:
providing a cooled, rotating mold roller having inwardly extending,
fixed, projection-forming cavities defined in its periphery; to the
exterior of the forming roller, applying molten plastic material
for filling the cavities and forming a base in the manner that
incorporates a hook engageable material on the side of the base
directed oppositely from the side in which the projections are
formed; withdrawing the fastener material from the forming roller,
including withdrawing the projections from the cavities; and either
in line or as a separate batch process, forming parting lines at
spaced intervals extending transversely of the resulting
material.
[0038] Another preferred method for forming a fastener material
comprises the steps of: forming loop product by a method comprising
the steps of forming a batt of loose, staple fibers; entangling the
fibers to produce a non-woven fabric of fibers joined at
entanglements, with loops of some of the fibers extending from at
least one side of the fabric; subsequently stretching the fabric to
tighten the entanglements to form knots, and combining the back
side of the loop product with the backside of a layer that carries
hook fasteners. In some embodiments, prior to combining the loop
product with the resin layer, a binding step is performed to bind
the knots to hold the fabric in its stretched condition. In some
cases, the combining step is effective to bind the knots to hold
the fabric in its stretched condition. In certain cases, the step
of combining is performed substantially simultaneously with forming
a layer that carries the hook fasteners. In a preferred embodiment,
the layer that carries the fastener hooks is formed by the method
of forming a running length of fastener material having integrally
formed with its base a large multiplicity of hook-forming fastener
projections extending from the surface of the base portion, the
method comprising: providing a cooled, rotating mold roller having
inwardly extending, fixed, projection-forming cavities defined in
its periphery; to the exterior of the forming roller, applying
molten plastic material for filling the cavities and forming a base
in the manner that incorporates the hook engageable material on the
side of the base directed oppositely from the side in which the
projections are formed, and withdrawing the fastener material from
the forming roller, including withdrawing the projections from the
cavities.
DESCRIPTION OF DRAWINGS
[0039] FIG. 1 is a side view of a dispenser holding a roll of
fastener strap material, its cover removed;
[0040] FIG. 1A is a front view of the dispenser;
[0041] FIG. 1B is a side view of the dispenser similar to FIG. 1,
with the cover shown in its position for loading;
[0042] FIG. 1C is a side view of the claw included in the dispenser
in FIG. 1;
[0043] FIG. 1D is a frontal view of the claw shown in FIG. 1C;
[0044] FIG. 2 is a diagram of a tensioning system of the dispenser
of FIG. 1;
[0045] FIG. 2A is a diagram of the tensioning system illustrated in
FIG. 2, with an alternatively shaped spring end;
[0046] FIG. 2B is a diagram of the tensioning system illustrated in
FIG. 2, having a spring with a thinned cross section;
[0047] FIG. 3 illustrates a fastener strap being pulled from the
dispenser;
[0048] FIG. 4, similar to FIG. 3, shows the strap material being
engaged by a detent immediately before separation of the leading
strap from the roll;
[0049] FIG. 5 is a top view of the strap of FIG. 4 being engaged by
the detent;
[0050] FIG. 6 is a view similar to FIG. 1 of another dispenser
construction, with an angled dispenser section, while FIG. 6A is a
side view of the cover used with the dispenser of FIG. 6;
[0051] FIG. 6B is a side view of a dispenser, having three spring
rollers to apply pressure to the strap material to be
dispensed;
[0052] FIG. 6C is a view similar to FIG. 1 of a dispenser
construction, having the tensioning system illustrated in FIG.
2B;
[0053] FIG. 7 is a top view of two straps defined by a line of
perforations and having a longitudinal slit in adjacent ends;
[0054] FIG. 7A is a magnified view of the perforation and slit of
FIG. 7;
[0055] FIG. 8 is a top view of two adjacent straps, having another
type of formation at their juncture;
[0056] FIG. 8A is a magnified view of the features illustrated in
FIG. 8;
[0057] FIG. 8B is a top view of two adjacent straps, having another
type of formation at their juncture, with the oval cut formation
somewhat displaced from the juncture;
[0058] FIG. 8C is a magnified view of the features illustrated in
FIG. 8B;
[0059] FIG. 9 is a top view of two adjacent straps, having another
type of formation at their juncture;
[0060] FIG. 9A is a magnified view of the features illustrated in
FIG. 9;
[0061] FIG. 10 is a longitudinal cross section view of a length of
strap material having fastener hooks on one side and loops on the
other side;
[0062] FIG. 10A is a magnified view of the material of FIG. 10;
[0063] FIG. 11 is a longitudinal cross-sectional view of a means
for manufacturing an integrally molded engaging member with backing
material attached, while FIG. 12 is a variation from FIG. 11, based
on the same general principles.
DETAILED DESCRIPTION
[0064] Referring to FIGS. 1-6, dispenser 10 has a housing structure
that defines supply receptacle 12, which is shaped to loosely hold
roll 14 of fastener strap (or other strip form member), to permit
rotation of the roll 14.
[0065] The receptacle 12 has a back wall 13, and is open at its
front to enable loading by axial insertion motion of the roll 14.
In FIG. 1B, tape cover 16 of the dispenser, shown in open position,
is pivotally mounted to rotate about axis Y to closed position
where it locks in place. After the roll 14 is loaded into the
dispenser below, cover 16 pivots closed about axis Y, to confine
the roll 14.
[0066] In one example, receptacle 12 and cover 16 are configured to
receive a roll 14 of up to 7.5 inches diameter while in other
embodiments the dispenser may be larger or smaller based on user
needs. The number of straps in the roll 14 is of course determined
by the roll diameter, the wind tension, and the length and
thickness of the individual straps. In one embodiment, the
dispenser holds a roll of 75 straps, each 18" long by 0.5" wide,
the straps having thickness of about 0.040 inches, forming a roll
of about 7.0 inches diameter. The wind tension is sufficient to
produce a firm roll which does not easily collapse and cause
jamming at the separation pin 22.
[0067] The strap material in certain cases is a fastener hook tape
or fastener loop tape, each adapted for hook and loop fastening. In
the presently preferred embodiment, it is a combination tape having
fastener hooks on one side and loops on the other as shown in FIGS.
10 and 10A. As will be described further below, in many
applications the hook comprises a plastic strip having an array of
fastener hooks molded integrally with the base layer and the loop
component is a light-weight, needled, and stretched product that is
in situ bonded to the base of the hook strip by the adhesive
properties of the synthetic resin layer that forms the
corresponding side of the base layer. The present embodiment of
FIGS. 1-6 is constructed to dispense such two-sided fastener
tape.
[0068] As shown in FIG. 1 and in detail in FIG. 2, in passing from
the supply roll 14 along a removal path, the strap 20 being removed
first passes over separation pin 22. Pin 22 extends parallel to
axis Z of the supply roll 14, and is located at a height even with
support surface 15. The effect of the strap passing under the
separation pin, combined with the weight of the roll that resists
its vertical movement, serves to break the bond between adjacent
hook and loop sides of the strap that is rolled upon itself.
Following separation pin 22, the tape 20 passes through a retarding
path 24 defined between a flat spring 26 and a land surface 30
defined by the housing structure of the dispenser.
[0069] In the embodiment shown, spring 26 is of blue spring steel,
flat in orientation. It extends from mount 29 as a cantilever and
has an end portion 28 that extends substantially parallel to land
30, against which it is spring biased, such that, in the absence of
tape 20, the spring portion 28 engages the land 30. Two screws 35
are perpendicular to the plane of the spring, and go up vertically.
Parallel to the right hand side beyond the screw holes 35 is the
end of the pocket 27. The depth of the pocket 27 provides enough
depth to recess the screw head.
[0070] In the presence of the tape, respective faces of the
fastener tape are engaged, the spring serving to maintain the
emerging part of the strap raised to be grasped and to frictionally
retard the tape as the tape is pulled from the dispenser. The
moderate predetermined drag provided by the retarding path ensures
that the product does not pull out too freely during normal
application of withdrawing tension, and it provides resistive
tension for enabling the initial phase of the singulating action
now to be described.
[0071] Following the retarding path, the fastener tape extends
freely through access region 32 at which it can be initially
grasped by the user. The tape path then extends through guide
channel 34 which is open at the top. Guide channel 34 is defined by
two side guide members 36, 37, disposed to be engaged by the edges
of the tape, and a downwardly curved lower surface 38 against which
the user draws the tape, as the user pulls downwardly and rightward
against the resistance provided by the spring which deflects. In
this embodiment, one of the guide members 37 is a portion of the
structure of the removable cover 16, and the other side guide 36 is
integral with the main housing of the dispenser.
[0072] Each guide 36, 37 is sufficiently rigid to engage and guide
the edges of the strip material which it is adapted to dispense.
The two guides 36, 37 thus provide a centering action, to guide the
tape so that it registers with a detent device 40 located in the
guide channel 34.
[0073] In the present embodiment, the detent device 40 is a
stationary claw, shaped much like a cat's claw, directed upwardly
and hooked backwardly to oppose motion of the strip. The claw
tapers slightly to a dull point, which is disposed to be slidably
engaged by the underside of the tape as the user, with downward and
forward force, draws the tape through the guide channel, against
curved surface 38. The tape thus slides over the apex of claw 40.
In this embodiment the claw 40 is centered in the middle of the
guide channel between the two side plates 36, 37. The shape of the
claw is shown in FIGS. 1B and 1C.
[0074] In FIG. 1A, a side view of the dispenser (cover 16 shown by
dashed lines), the elevation of claw 40 from the body 42 of the
claw holder is illustrated. In this embodiment claw 40 is formed
integrally with the structural body 42, the claw profile having
been provided by a separate piece that is inserted into the body
42. The claw body has mounting holes 41 for attachment. (In
production versions formed by injection molding, the claw is of
impact structural resin, e.g. acrylonitrile butadiene styrene
(ABS)/or high impact polystyrene, integrally formed with the
dispenser housing.)
[0075] The detent 40 between the two side plates, rounded as to
accommodate sliding movement of the tape, stands up and indents the
tape as the tape, being drawn by the user from the dispenser, is
pulled in rightward, downward motion (FIG. 3), overcoming drag
applied to the tape by spring 26. When a formation provided in the
strip material at the juncture of the leading strip units and the
following units reaches the claw, the claw penetrates the substance
of the tape, as shown in FIG. 4 and resists further motion of the
following strip unit to the degree that the line of weakness
ruptures under user's tension and the leading strip unit is
separated from the supply.
[0076] As illustrated in FIG. 6B, in order to work with the
fastener having tape adhesive on its backside, three spring rollers
17 replace the flat spring 26 and engage the adhesive. The rollers
are adjustably spring loaded; drag is provided to the strap by the
contact of the non-adhesive side of the product against the body of
the dispenser.
[0077] FIGS. 6 and 6A illustrate an alternative configuration of
the dispenser, where the dispensing section is angled to enable the
user to pull strip material straight out of the dispenser at an
upwardly inclined angle, when the dispenser is resting on a flat
surface.
[0078] In another embodiment, shown in FIG. 2A, spring 26 has a
curved end. This shape enables the user to smoothly pull a strap
out of the dispenser without scratching the strap's surface, and
without damaging printing which might be placed on the strap.
Alternatively, the end of the spring 26 can have a thinned cross
section, as illustrated in FIG. 6C and in detail in FIG. 2B. The
flexibility provided by the thinned section enables the strap to be
pulled out of the dispenser without relieving the drag provided by
rearward portions of the spring. When pulling tension is
discontinued, the end of the spring restores toward its straight
configuration, lifting the fastener into position to be
grasped.
[0079] Referring to FIG. 7, leading and trailing straps A and B are
shown with a line of perforations 50 between them, extending from
edge to edge of the strap, perpendicular to the longitudinal center
axis X of the strap.
[0080] The magnified view of FIG. 7A shows a blown-up version of
the slit 52 and perforations 50. In this embodiment, the slit is
approximately {fraction (1/2)} inch long, {fraction (1/4)} inch in
each of straps A and B, and is shown centered widthwise and extends
perpendicular to the line of perforations 50. The slit and
perforations are readily formed with a rotary die system or a
stamping system or a laser cutting system through which the strap
material is passed before it is formed in rolls.
[0081] A longitudinal slit 52 cut through the thickness of the
strap is formed in the adjacent end regions of straps A and B at
their juncture, this slit being aligned with longitudinal strap
axis X.
[0082] As Strap A is pulled from the roll 14, it moves across the
detent 40, shown in dotted lines. Referring also to FIG. 5, the
detent claw is in axial alignment with the center axis X of the
strap and slit 52.
[0083] As slit 52 approaches the detent 40, the claw feature 40
enters the leading part of slit 50 defined in lead strip A. Hook 40
penetrates the thickness of the tape, and, under downward and
rightward tension applied by the user to the lead unit, the tape is
free to move downwardly against the curved surface 38. The strap
continues to move from the dispenser until the end of the slit 52,
defined by the trailing strap unit B, reaches the claw. The claw
resists further movement of the strap and as the lead strap
continues to be pulled by the user, the materials breaks at the
line of perforations 50, freeing the lead strap unit A from the
supply. The spring 26, due to its strength and orientation, raises
the portion of the trailing strap unit emerging into region 32,
making the unit B available to be grasped. The action of spring 26
pulls strap B from the claw 40.
[0084] FIG. 8B illustrates still another tape construction which
has a line of perforations 50' similar to those in FIGS. 7 and 8.
However, the oval formation 52', which in FIG. 8 is placed directly
at the line of perforations, is moved some distance into the strap.
This arrangement results in the trailing strap protruding some
distance from the dispenser after the leading strap has been
severed, making it even more convenient for the user to grasp the
next strap.
[0085] The length and spring force of the spring 26 is selected to
perform its dual function of applying drag as the strap is
withdrawn, and of raising the strap material when the preceeding
strap breaks at the perforations, to position the next strap in a
convenient manner for the user to grasp.
[0086] Another tape construction, shown in FIG. 8, has a line at
perforations 50' similar to those of FIG. 7. However instead of a
straight slit, there is an oval cut formation 52'. The oval cut
formation provides a benefit in that it helps avoid longitudinal
rips in those tape constructions which are susceptible to
longitudinal ripping failure. The oval formation 52' serves to
spread the load applied by claw 40 to the trailing strap, and thus
lessen the stress applied to the trailing strap. The oval formation
is advantageous, for instance where the base layer of fastener hook
tape being dispensed is thin and not sufficiently reinforced to
prevent propagation of a failure line. A larger oval formation
helps keep the tape from catching on the claw.
[0087] The strap of FIGS. 9 and 9A shows straps, perforations, and
cut through similar to those of FIG. 8, with an additional crushed
area 54 around the oval, formed by a die that deforms by
compression. The crushed or depressed area enables the user to see
the beginning and end of the strap when it is in non-broken form,
as it approaches the detent.
[0088] For forming the crushed area in a hook or loop fastener
tape, a land is provided in the die or stamping tool of about
{fraction (1/16)}" width; its pressure crushes all the features of
the hook or the loop and is shaped to cut through on an edge of the
crushed region to form the oval cut.
[0089] The braking action of the spring which enables tension to be
applied on the strip and which prevents overfeed, enables the
mechanism to be used in one-handed operation. For this purpose, the
device is attached to a table, or is otherwise secured to resist
the tension applied by the user to the dispenser. (In the preferred
embodiment shown, hooks 44 are integrally molded in the base of the
dispenser, and the dispenser is packaged with a strip of adhesively
backed loop material 46. The loop material is adhered to a bench or
other surface, and the dispenser is releasably secured to the loop
materials, by resting upon it, with its hooks engaged in the
loops.)
[0090] The side guides 36, 37 provide alignment between the claw
feature 40 and the slit feature 52, 52' that have been cut into the
straps. The bigger the hole that is slit or punched through the
strap, the lower are the alignment requirements. However, a degree
of strength is required so that the straps stay connected until it
is necessary that they be broken. As one increases the size of the
feature which the claw 40 engages to hold the strap back, one
decreases the available strap width that remains for strength
purposes.
[0091] In another alternative, an angled slit is provided that
extends along the length of e.g. the center half of the tape, so
there is a 1/4" on each side, but angled. In this embodiment, the
claw feature 40 is able to find it, regardless of the alignment.
However, as the height of the claw feature of the detent 40
increases, the stability of the narrow web riding on the top of it
without guides becomes less sure. The detent 40 has to be
sufficiently high to find the slit; in the case of a diagonal cut,
it must extend through sufficiently that the strap cannot ride off
it so that it is captured.
[0092] The slit or other formation in the strap does not have to be
symmetrically disposed or centered so long as the dispenser enables
the strap to be guided into engagement with the hook or hooks or
other detent.
[0093] In another embodiment, the dispenser is manufactured by
injection molding techniques as two halves constructed to be
releasably joined (or permanently joined with a roll of tape inside
with which the dispenser is provided as a disposable unit). One
injection molded half, for instance, is constructed to slide over
the other half to capture the supply roll.
[0094] In a preferred example of such case, the separation pin 22,
the land 30, and the claw feature 40 are all injection molded as
integral parts of the plastic housing structure.
[0095] The spring 26 may be separately formed and inserted into the
assembled structure, or it may be injection molded to become
integrated with one of the injection molded parts. The spring may
for instance be blue spring steel or an impact-resistance
plastic.
[0096] Referring to FIGS. 10 and 10A, straps A and B are comprised
of rows of molded hooks 80, alternate rows facing in opposite
directions. The hooks molded integrally with base layer 82 and the
straps have in situ bonded to their lower surface non-woven loop
material 84 that forms loops of suitable dimensions to be
releasably engaged with hook 80. In a preferred form for use in low
cost applications, the non-woven fabric is a needled and stretched
loop material described further below.
[0097] The concepts that have been presented have wide application
where singulation of a fastener strip product is required.
Singulation with one hand is enabled.
[0098] In one preferred embodiment, the dispenser is constructed to
be portable, e.g. hand-held. It is held in one hand and brought to
the object that is to be wrapped. The user either pulls the strap
or pulls the dispenser so that the strap unrolls and is wrapped
about the object.
[0099] Using the hook and loop product from the dispenser offers
advantages of speed: once it is wrapped around the product, it
sticks to itself and is secure. Identification information can be
printed on the hook or loop side of the product.
[0100] Another advantageous feature is that the hook and the loop
product can be reused. For instance, if wires, fiber optics or
other items should need to be added or removed from the bundle, the
strap may be undone, the item added or removed, and the strap
re-engaged upon itself. The hook and loop product is not
significantly affected by moisture, cold, oil, grease and other
contaminants and maintains good appearance and its action is still
secure after multiple openings and closings. Furthermore, by using
the dispenser and applying the tape with the loop side in, a
cushioning effect is obtained upon the objects being bundled,
preventing abrasion or bruising.
[0101] An application is in bundling wires, cables, and hydraulic
and pneumatic lines. In the case of telecommunication fiber cables
where two-sided hook and loop products are commonly used, the
dispenser, for instance, enables significant reduction of the time
necessary to singulate straps.
[0102] The dispenser may be employed by packers for household
moving, to put tape on boxes, for instance with pressure-sensitive
materials. In one such case a hook tape is provided that has
pressure-sensitive adhesive on its back side and perforated as
illustrated here, and another tape which is loop that also has
pressure-sensitive adhesive, and is perforated in the same way.
Pre-formed pieces of those two fastener components are rolled upon
themselves and the rolls mounted in a dual dispenser, side by each,
to enable application of each to bags, boxes, etc. to provide a
releasable closure system that may be opened and closed
repeatedly.
[0103] This dispenser may be modified in many ways while still
employing important features. In one case a spring lever is
advantageously added to the side of the dispenser, associated with
an advancing mechanism that is activated by pushing the lever down,
to advance the strap. At the time one releases the lever, one would
cut a strap of desired length much like the action of traditional
paper tape dispensers. This permits use of the dispenser also with
strips that do not have the perforated lines of weakness and other
features.
[0104] The dispenser can also be automated in which the pulling
tension is applied by e.g. a robot or another device that grasps
the free end and draws it from the dispenser as in the manner
described.
[0105] The dispenser can be used with a variety of fastener strip
material, where the strap material has arrays of fastener elements
on both of its sides which are capable of being releasable fastened
together. Examples of such elements are hooks and loops. The hooks
can be molded integrally with a base layer and the material
providing loops including fibers that serve the function provided
by textile loops can be joined by the material of the base layer.
The loop side of the material can advantageously be a low-cost
non-woven web of entangled fibers of substantial tenacity with a
basis weight of between 1.8 to 2.5 ounces per square yard.
[0106] The loop material can advantageously comprise a batt of
loose, staple fibers that have been entangled and form a non-woven
fabric of fibers joined at entanglements, with loops of some of the
fibers extending from at least one side of the fabric.
Advantageously, needling of the batt is employed to form the
entanglements. In some embodiments, the non-woven fabric is bonded
in a stretched state in which tightened entanglements form knots.
The non-woven fabric can also be bonded in a stretched state by
resin integral with the material that forms the hook-form fastening
elements. Non-woven material for forming such fastener elements and
its method of manufacture is more fully described in our co-pending
application U.S. application Ser. No. 08/922,292, filed Sep. 3,
1997, entitled FASTENER LOOP MATERIAL, ITS MANUFACTURE, AND
PRODUCTS INCORPORATING THE MATERIAL, which is hereby incorporated
by reference.
[0107] As has previously been indicated with reference to FIGS.
7-10, fastener material suitable for use with the dispenser can be
prepared in the form of an extended length of strip material
defined as a series of detachable straps. For use with the
dispenser detent, the material has formations including weakened
parting lines at spaced intervals along its length and at least one
formation constructed and arranged to be engaged by the detent to
detain the remaining length of fastener material while the leading
strip is detached by rupture at the parting line by tension applied
to the parting line.
[0108] This material is provided with sufficient lateral stiffness
to enable it to be guided by edge guides, to register the detent
with the formation at the leading end of each strip. Furthermore,
it is advantageous that the material have sufficient thickness and
stiffness to spring from a bent configuration as it is pulled
across the detent to a more planar shape when the leading strip is
broken from the remaining material so that the freed end of the
remaining material lifts from the detent in a position where it can
be readily grasped by a user for dispensing the next successive
strip as the new leading strip.
[0109] Various types of fastener materials having pressure
sensitive adhesive on the side opposite the fastening elements are
provided with a release layer, and the lines of perforations are
made through both the fastener material and the release layer,
thereby enabling simultaneous separation of all layers by the
dispenser.
[0110] For certain applications, it is useful to have text printed
on the separable straps, for instance to provide label information
such as product codes, bar codes, identification of bundled
elements for telecommunication, instructions or warnings. Such
information may be pre-printed on the hook or loop portion of the
straps.
[0111] Advantageously following the techniques disclosed in U.S.
Patent Application "Fastener Loop Material, Its Manufacture and
Products Incorporating the Material", referenced above, a
lightweight, non-woven loop material is produced. It comprises a
non-woven web of entangled fibers of substantial tenacity, the
fibers forming a sheet-form body and hook-engageable free-standing
loops extending from the web body. The web is stretched before
bonding to produce spaced apart loop clusters extending from a very
thin web of taut fibers, and binder can be added to stabilize the
product in its stretched condition. The backside of the loop
product is then combined with the back side of a layer that carries
hook fasteners; this combining step can be effective to bind the
knots to hold the fabric in its stretched condition, to serve the
function of the binder just mentioned.
[0112] This hook-engageable material is then used for forming a
composite product having a large multiplicity of hook-form fastener
projections extending from the opposite surface. For this purpose a
cooled, rotating mold roller is provided having inwardly extending,
fixed, projection-forming cavities defined in its periphery, to the
exterior of the forming roller, molten plastic material is applied
for filling the cavities and forming a base in the manner that
incorporates the hook engageable material on the side of the base
opposite from the side in which the projections are formed, the
fastener material is withdrawn from the forming roller in a step
that includes withdrawing the projections from the cavities, and
either in line or as a separate batch process, parting lines are
formed at spaced intervals extending transversely of the strip
material.
[0113] Advantageously the non-woven material is laminated in situ
with the hook material using a layer of resin that forms the base
of the hook material to bond directly to the non-woven, as
generally taught by Kennedy et al. in U.S. Pat. No. 5,260,015.
[0114] In the case of using the specific example of FIG. 2 of the
Kennedy et al. patent (FIG. 11 of this application) a pre-formed
sheet material 90 is forced into the nip 96 at the same time as
molten plastic 93 is forced into the nip 96 to create strip
fastener tape, the sheet material bonding intimately with the
fastener to become an integral part of the structure of the strip
fastener.
[0115] Another case which utilizes the same general concept, is the
specific system illustrated in U.S. Pat. No. 5,441,687, Murasaki et
al. At the front end surface of the upper half of the extrusion
nozzle 1 shown in FIG. 1 of that patent (FIG. 12 of this
application), there is an upper arced surface 101a, the curve of
which mirrors that of the die wheel 102, while at the front end
surface of the lower half of the nozzle 101, there is a further
lower arced surface 101b, the curve of which also mirrors that of
the die wheel.
[0116] A guide channel 101d through which the non-woven material is
introduced is formed in the lower half of the extrusion nozzle 101.
A rear pressure roller 108a applies pressure between the sheet of
molten resin extruded from the extrusion nozzle, to join the
non-woven material 103 to be attached to the resin.
[0117] Thus in operation the molten resin extruded from the
extrusion nozzle 101 is forced into the gap between the die wheel
102 and the lower arced surface 101b, and fills up the hook molding
cavities 105 along with a base layer 104a of fixed thickness and
width. At the same time as this molding process is taking place,
the backing material 103 is guided up through the backing material
guide channel 101d in the extrusion nozzle 101 and is pressed
against the surface of the molten base layer 104a by the rear
pressure roller 108a to firmly join them together, so that the
bases of the loops in the backing material are firmly held by the
resin so that the loops will hold their shape well and will be very
durable.
[0118] Various preferred embodiments of the invention have been
presented. However, the illustrations are not exhaustive; it should
be readily apparent to one skilled in the art that other
configurations of the dispenser and the strap material are
possible, including use of alternative strap material
configurations and arrangements within the dispenser.
* * * * *