U.S. patent application number 10/606903 was filed with the patent office on 2004-12-30 for fastener product with multiple engagement angles.
Invention is credited to Kurtz, Wallace L. JR., Neeb, Alexander J., Pierce, Joseph E., Tachauer, Ernesto S., VanBenschoten, Brian J..
Application Number | 20040261232 10/606903 |
Document ID | / |
Family ID | 33540162 |
Filed Date | 2004-12-30 |
United States Patent
Application |
20040261232 |
Kind Code |
A1 |
Kurtz, Wallace L. JR. ; et
al. |
December 30, 2004 |
Fastener product with multiple engagement angles
Abstract
A method of forming a fastener product is provided that includes
providing a continuous, sheet-form base having an array of fastener
elements including molded stems that extend outwardly therefrom.
The sheet-form base is split between adjacent rows of the molded
fastener elements to form elongated fastener filaments. The
fastener filaments are twisted individually to reorient the
fastener elements to extend in multiple directions from a common
core.
Inventors: |
Kurtz, Wallace L. JR.;
(Lunenburg, MA) ; VanBenschoten, Brian J.;
(Rochester, NH) ; Tachauer, Ernesto S.; (Bedford,
NH) ; Pierce, Joseph E.; (Appleton, WI) ;
Neeb, Alexander J.; (Alpharetta, GA) |
Correspondence
Address: |
FISH & RICHARDSON PC
225 FRANKLIN ST
BOSTON
MA
02110
US
|
Family ID: |
33540162 |
Appl. No.: |
10/606903 |
Filed: |
June 26, 2003 |
Current U.S.
Class: |
24/452 |
Current CPC
Class: |
A44B 18/0019 20130101;
B29L 2031/729 20130101; A44B 18/0042 20130101; A61F 13/625
20130101; Y10T 24/2792 20150115; B29C 2043/465 20130101 |
Class at
Publication: |
024/452 |
International
Class: |
A44B 018/00 |
Claims
What is claimed is:
1. A method of forming a fastener product, the method comprising
providing a continuous, sheet-form base having an array of fastener
elements including molded stems extending in rows outwardly from
the continuous, sheet-form base; splitting the base between
adjacent rows of the fastener elements to form elongated fastener
filaments; and twisting the fastener filaments individually to
reorient the fastener elements to extend in multiple directions
from a common core.
2. The method of claim 1 wherein the fastener elements have heads
that are hook-shaped overhanging the base in one or more discrete
directions.
3. The method of claim 1 wherein the fastener elements have heads
that are mushroom-shaped overhanging the base in multiple
directions.
4. The method of claim 1 further comprising splitting the
continuous, sheet-form base longitudinally.
5. The method of claim 1 wherein the fastener filaments each have
only one row of fastener elements.
6. The method of claim 1 further comprising winding at least two of
the twisted fastener filaments together to form a yarn having
fastener elements extending outwardly in multiple directions.
7. The method of claim 1 further comprising depositing twisted
fastener filaments on a substrate to form a field of exposed
fastener elements extending from the substrate.
8. The method of claim 7, wherein the twisted fastener filaments
are deposited on the substrate in a predetermined pattern.
9. The method of claim 8, wherein the predetermined pattern
approximates a line extending substantially parallel to a
longitudinal edge of the substrate.
10. The method of claim 8, wherein the predetermined pattern is
wave-like.
11. The method of claim 7, wherein the twisted fastener filaments
are deposited randomly on the substrate.
12. The method of claim 1 further comprising weaving the twisted
fastener filaments to form a woven material.
13. The method of claim 1 further comprising weaving at least one
twisted fastener filament with a non-fastener filament to form a
woven material.
14. The method of claim 1, wherein twisting the fastener filaments
individually to reorient the molded fastener elements to extend in
multiple directions from a common core further includes heating the
fastener filaments.
15. The method of claim 1, wherein prior to providing the substrate
the method includes molding the continuous, sheet-form base
including fastener element stems, the stems integrally molded with
and extending from the sheet-form base.
16. The method of claim 15, wherein the fastener elements are
formed on a mold roll defining a plurality of hook-shaped fastener
element cavities to form fastener elements having head portions
extending radially outwardly in one or more discrete
directions.
17. The method of claim 15 further including deforming distal ends
of the stems to form overhanging heads.
18. The method of claim 1, wherein twisting the fastener filaments
individually to reorient the molded fastener elements to extend in
multiple directions from a common core further includes cooling the
fastener filaments.
19. A method of forming a fastener product, the method comprising
molding rows of fastener elements formed of synthetic resin on a
mold roll defining a plurality of fastener element cavities, the
fastener elements having stems extending outwardly from and
integral with a continuous, sheet-form base; and splitting the
continuous base between individual rows of molded fastener elements
to form elongated fastener filaments, each fastener filament having
one row of fastener elements.
20. The method of claim 19 wherein the fastener elements have heads
that are hook-shaped overhanging the base in one or more discrete
directions.
21. The method of claim 19 wherein the fastener elements have heads
that are mushroom-shaped overhanging the base in multiple
directions.
22. The method of claim 19 further comprising splitting the
continuous sheet-form base in the machine direction.
23. The method of claim 19 further comprising chopping the fastener
filaments into a plurality of filament pieces.
24. The method of claim 23 further comprising applying the filament
pieces to a material.
25. The method of claim 19 further comprising winding at least two
fastener filaments to form a yarn having fastener elements
extending in multiple directions.
26. A method of forming fastener filament material, the method
comprising molding a continuous, sheet-form base having rows of
fastener elements formed of synthetic resin, the fastener elements
having stems that extend outwardly from and integral with the
continuous, sheet-form base; splitting the continuous base between
adjacent rows of the molded fastener elements to form elongated
fastener filaments; cutting the fastener filaments into discrete
lengths of fastener filament strands; and depositing the fastener
filament strands on a substrate to form a field of exposed fastener
elements extending from the substrate.
27. The method of claim 26 wherein the fastener elements have heads
that are hook-shaped overhanging the base in one or more discrete
directions.
28. The method of claim 26 wherein the fastener elements have heads
that are mushroom-shaped overhanging the base in multiple
directions.
29. The method of claim 26 wherein splitting the continuous
sheet-form base further includes twisting the fastener filaments to
reorient the molded fastener elements to extend in multiple
directions from a common core.
30. The method of claim 26 further comprising attaching the
deposited fastener filament strands to the substrate.
31. The method of claim 30 wherein the substrate includes a
plurality of fibers sized to engage the fastener elements.
32. The method of claim 31 wherein the fastener filament strands
are attached to the substrate by engaging the fastener elements
with the fibers of the substrate.
33. The method of claim 30 wherein the fastener filament strands
are attached to the substrate by bonding the fastener filaments to
a surface of the substrate.
34. The method of claim 26 wherein the substrate comprises
non-woven fibers.
35. The method of claim 26 wherein the fastener elements are sized
to engage one of loops of a loop material and the substrate to a
greater extent and the other to a lesser extent.
36. The method of claim 26, wherein the fastener filament strands
are deposited randomly on the substrate.
37. The method of claim 26, wherein the fastener filament strands
are deposited on the substrate in a predetermined pattern.
38. A twisted fastener filament comprising an outer surface twisted
about a common core; and a series of fastener elements disposed
about the core along its length; each fastener element comprising a
stem integrally molded with the outer surface of the core with a
distal head overhanging the outer surface.
39. The method of claim 38 wherein the fastener elements have heads
that are hook-shaped overhanging the outer surface in one or more
discrete directions.
40. The method of claim 38 wherein the fastener elements have heads
that are mushroom-shaped overhanging the outer surface in multiple
directions.
41. A method of forming a nonwoven web comprising fastener filament
material, the method comprising molding a continuous, sheet-form
material having rows of fastener elements formed of synthetic
resin, the fastener elements having stems that extend outwardly
from and integral with the continuous, sheet-form material;
splitting the continuous sheet of material between adjacent rows of
the molded fastener elements to form elongated fastener filaments;
twisting the fastener filaments individually to reorient the molded
fastener filaments to extend in multiple directions from a common
core; cutting the fastener filaments into discrete lengths of
fastener filament strands; and forming a nonwoven web material
comprising the discrete lengths of fastener filament strands.
42. The method of claim 41 wherein the method of forming a nonwoven
web is selected from the group consisting of airlaying, carding and
wetlaying.
43. The method of claim 42 wherein the nonwoven web material
further comprises thermoplastic staple fibers.
44. The method of claim 42 wherein the nonwoven web material
further comprises cellulosic fibers.
45. The method of claim 42 further comprising bonding the nonwoven
web material.
46. The method of claim 45 wherein the bonding step is a bonding
process selected from the group consisting of entanglement bonding,
through-air bonding, thermal point bonding, ultrasonic bonding and
adhesive bonding.
47. A personal care product comprising a nonwoven web made by the
method of claim 41.
48. A protective garment comprising a nonwoven web made by the
method of claim 41.
49. A laminate material comprising a nonwoven web formed by the
method of claim 41.
50. A personal care product comprising the laminate material of
claim 49.
51. A protective garment comprising the laminate material of claim
49.
52. A fastener product comprising: a first twisted fastener
filament including an outer surface twisted about a core and a
series of stems disposed about the core along its length; and a
second twisted fastener filament wound about the first twisted
fastener filament, the second twisted fastener filament including
an outer surface twisted about a core and a series of stems
disposed about the core along its length.
53. The fastener product of claim 52, wherein the stems further
include heads that overhang the outer surface.
54. The fastener product of claim 53, wherein the heads are
hook-shaped overhanging the outer surface in one or more discrete
directions.
55. The fastener product of claim 53, wherein the heads are
mushroom-shaped overhanging the outer surface in multiple
directions.
56. A method of forming a fastener product comprising: providing a
strip of material having rows of fastener elements formed of
synthetic resin, the fastener elements having stems that extend
outwardly from the strip of material; and winding the material
about the periphery of an inner member to reorient the stems to
extend in multiple directions.
57. The method of claim 56 further including extruding resin to
form the inner member.
58. The method of claim 56, wherein the inner member comprises a
rod.
59. The method of claim 58, wherein the rod is electrically
conductive.
60. The method of claim 56, wherein the inner member is
tubular.
61. The method of claim 60, wherein the inner member defines a
conduit for extending about an electrically conductive element.
62. The method of claim 56 further including attaching the strip of
material to the periphery of the inner member.
63. The method of claim 56 further including heating the strip of
material.
64. The method of claim 56 further including cooling the strip of
material.
65. The method of claim 56, wherein winding the strip of material
includes rotating the inner member.
66. The method of claim 56, wherein providing the strip of material
includes molding a continuous, sheet-form material having rows of
fastener elements formed of synthetic resin, the fastener elements
having stems that extend outwardly from and integral with the
continuous, sheet-form material; and splitting the continuous sheet
of material between adjacent rows of the molded stems to form the
strip of material.
67. The method of claim 56 wherein the fastener elements have heads
that are hook-shaped overhanging the outer surface in one or more
discrete directions.
68. The method of claim 56 wherein the fastener elements have heads
that are mushroom-shaped overhanging the outer surface in multiple
directions.
69. A fastener product comprising: an inner member; and a strip
material wound about the periphery of the inner member, the strip
material having rows of fastener elements formed of synthetic
resin, the fastener elements having stems that extend outwardly
from and integrally with a surface of the strip material.
70. The fastener product of claim 69, wherein the inner member
includes resin.
71. The fastener product of claim 69, wherein the inner member
comprises a rod.
72. The fastener product of claim 71, wherein the rod is
electrically conductive.
73. The fastener product of claim 69, wherein the inner member is
tubular.
74. The fastener product of claim 73, wherein the inner member
defines a conduit for extending about an electrically conductive
element.
75. The fastener product of claim 69, wherein the strip of material
is attached to the periphery of the inner member.
76. The fastener product of claim 69, wherein the fastener elements
have heads that are hook-shaped overhanging the outer surface in
one or more discrete directions.
77. The fastener product of claim 69, wherein the fastener elements
have heads that are mushroom-shaped overhanging the outer surface
in multiple directions.
Description
TECHNICAL FIELD
[0001] This invention relates to fastener products and more
particularly to fastener products having multiple engagement
angles.
BACKGROUND
[0002] This invention relates generally to touch fasteners, and
specifically to touch fasteners for engaging fibers and to methods
and apparatus for their manufacture.
[0003] There has been much development over the last thirty years
in the field of hook-and-loop fasteners. Early touch fastener
products of this type consisted of two mating tapes, each being
knit or woven. One tape would include loops of filament woven into
a base, and the other would include filaments woven to form loops
and then cut to form hooks. In some cases free ends of drawn
plastic filaments on the male tape would be melted to form
protruding heads. This shape of fastener element is sometimes
called a "mushroom", to distinguish it from "hook"-shaped elements
with re-entrant crooks.
[0004] More recently, continuous molding of fastener elements
extending from a common sheet-form resin base has resulted in less
expensive and thinner male tapes. Significant improvements in this
area include the development of continuous fastener tape molding
using fixed mold cavities (see Fischer, U.S. Pat. No. 4,794,028),
and the ability to provide loops on the back side of the male
fastener tape as the fastener tape substrate and elements are being
formed (see Kennedy et al., U.S. Pat. No. 5,260,015), thus creating
a composite fastener tape capable of fastening to itself.
[0005] Much recent development has been directed at making fastener
products having fastener elements that extend in a common
orientation. As discussed below, there is a need or desire for a
releasable fastener having multiple angles of engagement.
SUMMARY
[0006] In various aspects, the present invention features fastener
products having individual fastener elements with stems integrally
molded with a base and extending in different directions.
[0007] In one aspect, the invention features a method of forming a
fastener product and includes providing a continuous, sheet-form
base having an array of fastener elements including molded stems
extending outwardly from the continuous, sheet-form base and
splitting the base between adjacent rows of the molded fastener
elements to form elongated fastener filaments and twisting the
fastener filaments individually to reorient the fastener elements
to extend in multiple directions from a common core.
[0008] Implementations may include one or more of the following
features. The method includes splitting the base longitudinally
along the continuous, sheet-form base. The base is split so that
the fastener filaments each have only one row of fastener
elements.
[0009] In some embodiments, the method includes winding at least
two of the twisted fastener filaments together to form a yarn
having fastener elements extending outwardly in multiple
directions.
[0010] In some cases, the method includes depositing twisted
fastener filaments on a substrate to form a field of exposed
fastener elements extending from the substrate. Where the twisted
fastener filaments are deposited on the substrate, the twisted
fastener filaments are deposited on the substrate in a
predetermined pattern. In these embodiments, the predetermined
pattern can approximate a line extending substantially parallel to
a longitudinal edge of the substrate. The predetermined pattern can
also be wave-like. In other embodiments, the twisted fastener
filaments are deposited randomly on the substrate.
[0011] In some embodiments, the method includes weaving the twisted
fastener filaments to form a woven material. The twisted fastener
filaments can be woven with a non-fastener filament to form the
woven material.
[0012] In some cases, twisting the fastener filaments individually
to reorient the molded fastener elements to extend in multiple
directions from a common core further includes heating the fastener
filaments.
[0013] Some embodiments include prior to providing the substrate,
molding the continuous, sheet-form base having stems of fastener
elements, the stems integrally molded with and extending from the
substrate.
[0014] In some cases, the method includes cooling the twisted
fastener filament.
[0015] In another aspect, the invention features a method of
forming a fastener product and includes molding rows of fastener
elements formed of synthetic resin on a mold roll, the mold roll
has a plurality of fastener element cavities and the fastener
elements include stems extending outwardly from and integral with a
continuous, sheet-form base; and splitting the continuous base
between individual rows of molded fastener elements to form
elongated fastener filaments, each fastener filament having one row
of fastener elements.
[0016] Implementations of may include one or more of the following
features. For example, the method includes splitting the continuous
sheet of material in the machine direction.
[0017] In some cases, the method includes chopping the fastener
filaments into a plurality of filament pieces. This can further
include applying the filament pieces to a material.
[0018] In some embodiments, the method further includes winding at
least two fastener filaments to form a yarn having fastener
elements extending in multiple directions.
[0019] In yet another aspect, the invention features a method of
forming fastener filament material and includes molding a
continuous, sheet-form base having rows of fastener elements formed
of synthetic resin, the fastener elements having stems that extend
outwardly from and integral with the continuous, sheet-form base;
splitting the continuous base between adjacent rows of the molded
fastener elements to form elongated fastener filaments; cutting the
fastener filaments into discrete lengths of fastener filament
strands; and depositing the fastener filament strands on a
substrate to form a field of exposed fastener elements extending
from the substrate.
[0020] Implementations may include one or more of the following
features. For example, the method includes twisting the fastener
filaments to reorient the molded fastener elements to extend in
multiple directions from a common core.
[0021] In some cases, the method includes attaching the deposited
fastener filament strands to the substrate. The fastener filaments
can be attached to the substrate by engagement of the fastener
elements with fibers. Also, the fastener filaments can be attached
to the substrate by bonding the fastener filaments to a surface of
the substrate.
[0022] In some embodiments, the substrate has a plurality of fibers
sized to engage the fastener elements.
[0023] Some embodiments include the substrate having non-woven
fibers.
[0024] In some cases, the fastener elements are sized to engage one
of loops of a loop material and the substrate to a greater extent
and the other to a lesser extent.
[0025] In some embodiments, the fastener filament strands are
deposited randomly on the substrate. Alternatively, in other
embodiments, the fastener filament strands are deposited on the
substrate in a predetermined pattern.
[0026] In another aspect, the invention features a method of
forming a nonwoven web comprising fastener filament material and
includes molding a continuous, sheet-form material having rows of
fastener elements formed of synthetic resin, the fastener elements
having stems that extend outwardly from and integral with the
continuous, sheet-form material; splitting the continuous sheet of
material between adjacent rows of the molded fastener elements to
form elongated fastener filaments; twisting the fastener filaments
individually to reorient the molded fastener filaments to extend in
multiple directions from a common core; cutting the fastener
filaments into discrete lengths of fastener filament strands and
forming a nonwoven web material comprising the discrete lengths of
fastener filament strands.
[0027] Implementations may include one or more of the following
features. For example, the method of forming a nonwoven web is
selected from the group consisting of airlaying, carding and
wetlaying. The group can include thermoplastic staple fibers and/or
cellulosic fibers.
[0028] In some cases, the method includes bonding the nonwoven web
material. Bonding can include a bonding process selected from the
group consisting of entanglement bonding, through-air bonding,
thermal point bonding, ultrasonic bonding and adhesive bonding. The
bonded material can be used to form a protective garment.
[0029] In some embodiments, the nonwoven web material forms a
laminate material.
[0030] In some cases, the nonwoven material forms a personal care
product.
[0031] The nonwoven web of some embodiments forms a protective
garment.
[0032] In yet another aspect, the invention features a method of
forming a fastener product including providing a sheet-form
material having rows of fastener elements formed of synthetic
resin, the fastener elements having stems that extend outwardly
from the continuous, sheet-form material; and winding the material
about the periphery of an inner member to reorient the stems to
extend in multiple directions.
[0033] Implementations may include one or more of the following
features. For example, the method includes extruding resin to form
the inner member.
[0034] In some cases, the inner member is a rod.
[0035] In some embodiments, the inner member is electrically
conductive.
[0036] The inner member of some embodiments is tubular. The tubular
inner member can extend about an electrically conductive
element.
[0037] In some cases, the method includes attaching the strip of
material to the periphery of the inner member.
[0038] In some embodiments, the method includes heating and/or
cooling the strip of material.
[0039] In some cases, winding the strip of material includes
rotating the inner member.
[0040] Some embodiments further include providing the strip of
material by molding a continuous, sheet-form material having rows
of fastener elements formed of synthetic resin, the fastener
elements having stems that extend outwardly from and integral with
the continuous, sheet-form material and splitting the continuous
sheet of material between adjacent rows of the molded stems to form
the strip of material.
[0041] In another embodiment, the invention features a method of
forming a fastener product and includes continuously introducing at
least two streams of molten resin to a gap defined adjacent a
periphery of a rotating mold roll, such that each stream of resin
forms a respective strip-form base of a fastener filament at the
periphery of the mold roll and fills select ones of cavities
defined in the rotating mold roll to form fastener element stems
extending integrally from the respective strip-form base;
solidifying the resin streams and stripping the streams of resin
from the periphery of the mold roll by pulling the solidified
fastener element stems from their respective cavities to form at
least two elongated fastener filaments.
[0042] Implementations of the foregoing aspects can include one or
more of the following features. For example, the fastener elements
have heads that are hook-shaped overhanging the base in one or more
discrete directions. To form the hook-shaped heads, the cavities
are hook-shaped. In a variation, the fastener elements have heads
that are mushroom-shaped overhanging the base in multiple
directions. To form the mushroom-shaped heads, the method includes
deforming distal ends of the stems to form overhanging heads.
[0043] In some embodiments, methods include winding at least two
fastener filaments to form a yarn having fastener elements
extending in multiple directions.
[0044] In another aspect, the invention features a twisted fastener
filament including an outer surface twisted about a common core and
a series of fastener elements disposed about the core along its
length; each fastener element comprising a stem integrally molded
with the outer surface of the core with a distal head overhanging
the outer surface.
[0045] In another aspect, the invention features a fastener product
including a first twisted fastener filament including an outer
surface twisted about a core and a series of stems disposed about
the core along its length. The fastener product also includes a
second twisted fastener filament wound about the first twisted
fastener filament, the second twisted fastener filament including
an outer surface twisted about a core and a series of stems
disposed about the core along its length.
[0046] In another aspect, the invention features a fastener product
including an inner member and a strip material wound about the
periphery of the inner member. The strip material has rows of
fastener elements formed of synthetic resin and the fastener
elements include stems that extend outwardly from and integrally
with a surface of the strip material.
[0047] Implementations of this aspect may include one or more of
the following. For example, the inner member is a rod. The inner
member is tubular. The inner member can be electrically conductive.
The tubular inner member can have a conduit for extending about an
electrically conductive member. The strip material is attached to
the periphery of the inner member.
[0048] Implementations of any of the foregoing may include one or
more of the following features. For example, the stems have heads
that overhang the outer surface. The heads can be hook-shaped
overhanging the outer surface in one or more discrete directions
and/or the heads can be mushroom-shaped overhanging the outer
surface in multiple directions.
[0049] Various aspects of the invention can provide a fastener
filament, twisted or untwisted, that can be used in the production
of various fastener products. The twisted fastener filaments and/or
products having twisted and/or untwisted fastener filaments have
multiple angles of engagement due to the reorientation of the
fastener elements by, for example, winding and/or twisting of the
fastener filaments. These multiple angles of engagement increase
the probability for successful engagement with, for example, a loop
product and/or nonwoven product.
[0050] The details of one or more embodiments of the invention are
set forth in the accompanying drawings and the description below.
Other features, objects, and advantages of the invention will be
apparent from the description and drawings, and from the
claims.
DESCRIPTION OF DRAWINGS
[0051] FIG. 1 illustrates a method and apparatus used to form a
fastener product.
[0052] FIG. 1A is a top view of a laminate sheet being split.
[0053] FIG. 2 illustrates a method and apparatus used to form a
fastener product.
[0054] FIG. 3 illustrates a cross-sectional, sectional view of a
mold roll having sections of extended diameter.
[0055] FIG. 3A illustrates a cross-sectional, sectional view of a
substrate having a splitting feature formed by the mold roll of
FIG. 3.
[0056] FIG. 4 illustrates a method and apparatus used to form a
fastener product.
[0057] FIG. 5 illustrates a method and apparatus used to form a
fastener product with a backing material.
[0058] FIG. 5A illustrates a cross-sectional view of a fastener
product along line AA of FIG. 5.
[0059] FIG. 5B illustrates a plan view of a fastener product formed
by the method of FIG. 5.
[0060] FIG. 6 illustrates another method and apparatus used to form
a fastener product.
[0061] FIG. 6A is a detail illustration of cut or chopped fastener
filaments.
[0062] FIG. 6B is a plan view of a fastener product formed by the
method illustrated by FIG. 6 along line B.
[0063] FIG. 6C is a detail illustration of cut or chopped twisted
fastener filaments.
[0064] FIG. 7 illustrates a method and apparatus used to form a
woven fastener product.
[0065] FIG. 7A illustrates a sectional plan of a woven fastener
product.
[0066] FIG. 7B illustrates an alternative sectional plan view of a
woven fastener product.
[0067] FIG. 8 illustrates a spooled fastener filament and method
and apparatus for forming a twisted fastener filament.
[0068] FIG. 9A pictures a fastener product having multidirectional
hooks.
[0069] FIG. 9B is a larger-scale picture of the product of FIG.
7A.
[0070] FIG. 10A pictures a fastener product having mushroom-shaped
fasteners extending in multiple radial directions.
[0071] FIG. 10B is a larger-scale picture of the product of FIG.
8A.
[0072] FIG. 11 illustrates a method and apparatus for forming a
fastener product.
[0073] FIG. 12 is a sectional view of a fastener product formed by
the method of FIG. 11.
[0074] FIG. 12A is a side view of the product of FIG. 12.
[0075] FIG. 13 illustrates a side-view of a fastener product.
[0076] FIG. 13A illustrates a cross-sectional view of the fastener
product of FIG. 9.
[0077] FIG. 14 illustrates woven fastener products.
[0078] FIG. 15 illustrates a fastener product applied to loop
material.
[0079] FIG. 16 illustrates a fastener yarn.
[0080] Like reference symbols in the various drawings indicate like
elements.
DETAILED DESCRIPTION
[0081] Referring to FIGS. 1-7, methods of producing fastener
products are shown that build on the methods described by Fischer
(U.S. Pat. No. 4,794,028), which is incorporated herein by
reference. Referring particularly to FIG. 1, the method employs a
rotating mold roll 10 and a pressure roll 12 for molding a
synthetic resin. The mold roll 10 and the pressure roll 12 provide
a gap 14 into which the synthetic resin is directed by an extruder
16. An array of cavities 11 extends from the surface and
substantially about the entire periphery of mold roll 10. Pressure
in the gap 14 forces resin to enter and at least partially fill
cavities 11, while excess resin forms a base substrate from which
the fastener elements extend. The molded product may also be cooled
on the mold roll until the solidified fastener elements are
stripped from their fixed cavities by a stripper roll 13.
[0082] In some embodiments, cavities 11 of mold roll 10 have a head
engaging portion to form, for example, discrete, spaced-apart hooks
sized to engage a mating material. In these embodiments, the
solidified product stripped from the mold roll has fastener
elements capable of engagement. However, in other embodiments, the
cavities may have only a stem forming portion (see FIG. 2). In
these embodiments, the fastener product that is stripped from the
mold roll has stems extending from the base that can be
post-treated to form engaging heads.
[0083] Referring still to FIG. 1, after the sheet-form array of
fastener elements 18 is formed and removed from the mold roll, the
sheet is split in the machine direction between individual columns
of fastener elements 18 by a splitting device 20, such as an
ultrasonic cutter or a rotational or stationary blade, for example,
(see FIG. 1A) forming a series of elongated fastener filaments 22,
each having only one column of fastener elements. Although FIG. 1A
shows only two columns of hooks, tapes with, for example, tens or
hundreds of columns of hooks can be molded and split. In some
cases, each cut filament has two or more columns of elements.
Because fastener filaments 22 are formed in the machine direction,
the filaments 22 can be fed to an adjacent station in a continuous
process. Each elongated fastener filament 22 is twisted by a
twisting device 24 into elongated twisted fastener filaments 26.
Prior to twisting, the elongated fastener filaments 22 may be
heated to soften the plastic, then, subsequent to twisting, cooled
to allow the twisted form to set into a continuous column having an
array of fastener elements 18 extending radially in multiple
directions, to form hook fasteners with multiple planes of
engagement. Alternatively, the fastener filaments can first be
twisted, then heated and subsequently cooled. The twisted fastener
filaments 26 are then transferred directly to a storage roll 28
from which the filaments 26 may be dispensed at a later time.
[0084] Referring to FIG. 2, an alternative embodiment is
illustrated including a topping roll 30. Synthetic resin is
directed into a gap 14 and then formed into a sheet-form array of
stems 34 projecting from a base. The stems 34 are reheated by
heater 38, thus softening the plastic to allow for subsequent
forming of a fastener element. The heated stems 34 are then shaped
by topping roll 30, which applies pressure to distal ends of the
fastener elements 34 thus forming the fastener elements 35 with
heads that overhang the base. As described above, the sheet of
fastener elements 35 may then be split between columns of fastener
elements 35 into elongated fastener filaments 37. The fastener
filaments can then be twisted into a final shape and/or diverted to
a storage roll, as examples. The stem ends may be heated in a
non-contacting process, such as by flame or hot wire, or in a
contacting process, such as by heating roll 30. A suitable
non-contacting process is provided in U.S. Pat. No. 6,248,276, the
entire contents of which are hereby incorporated by reference.
[0085] To facilitate splitting of the sheet-form molded substrate,
a separation groove can be molded into the substrate. Referring to
FIG. 3, mold roll 200 has splitting rings 202 having a region of
increased diameter shaped to create the separation grooves T (FIG.
3A). Groove T is an integral, relatively thin, rupturable joint
that permits easy separation of filaments. Roll 200 has two
sections 204 adjacent each ring 202 that define mold cavities 206
shaped to form stems 34. Other splitting features include embedded
yarns, perforations, or the like.
[0086] Referring now to FIG. 4, an alternative to splitting the
resin sheet between rows of stems is to extrude individual,
relatively narrow columns 208 of heated resin and to deliver those
columns of resin to gap 14. As in the methods described by FIGS. 1
and 2, resin from each of the columns enters select ones of the
cavities 11, forming molded stems, while excess resin from each
column forms a base from which the molded stems extend. Exiting the
gap 14 are individual strands of filaments having integrally molded
stems extending from the base that can be cooled on the mold roll
and then removed.
[0087] Referring now to FIG. 5, the twisted fastener filament 26 is
added to a surface of a substrate 40. Referring also to FIG. 5A,
following heating and/or twisting of the filament, the twisted
fastener filament 26 is placed on substrate 40 along the machine
direction of the substrate 40, with the fastener elements 34
extending radially from a central axis of each filament. The
twisted fastener filament 26 placement on the substrate can trace a
repeating pattern, such as longitudinally extending lines, curves,
waves, etc., and/or the placement can be random (see FIG. 5B). The
twisted fastener filament 26 may be bonded to the substrate 40 by
heating the filament 26 and/or by adhering the filament 26 to a
surface of the substrate 40, or the fastener elements 18 of the
fastener filaments 26 may be attached to loops and/or fibers
extending from a surface of the substrate 40. It should be noted
that the untwisted fastener filaments may also be attached and/or
bonded to substrate 40.
[0088] FIG. 6 illustrates another embodiment where untwisted
fastener filaments 42 are being formed by passing synthetic resin
between a mold roll 10 and a pressure roll 12 and then splitting a
molded sheet-form array of fastener elements 18 with a splitting
device 20 forming fastener filaments 22, as described above. The
fastener filaments are then cut or chopped into pieces 50, each
piece 50 having fastener elements 18 extending from a base 44 (see
FIG. 6A), by a chopping device 46 and then applied randomly to a
substrate 48. The chopped pieces 50 are cut to a predetermined
length, each piece preferably having at least one fastener element
extending from a base of piece 50. The dimensions of the untwisted
pieces can be selected to cause a significant portion of the pieces
to fall with their fastener elements extending upward or at varying
engagement angles. The pieces may be randomly distributed in
orientation (see FIG. 6B). As a variation, the filaments, twisted
or untwisted, may be cut into discrete lengths and applied to the
substrate in a predetermined pattern or arrangement (not shown).
For example, the filaments can be cut and then applied to the
substrate in the cross-machine direction in a spaced-apart
arrangement. In some cases, the pieces 50 are cut so as to each
have several fastener elements. The filament pieces 50 may be
bonded to the substrate 48 by thermal bonding, applying adhesive
and/or other similar techniques. Alternatively, the fastener
elements 18 of the fastener filament pieces 50 may be attached to
loops and/or fibers extending from a surface of the substrate 48.
In some cases, the filaments are twisted before being cut into
pieces 50 and applied to the substrate 48, to increase the
randomness of the angles of engagement (see FIG. 6C).
[0089] In yet another embodiment, a twisted or untwisted fastener
filament may be cut into discrete lengths of fastener filament
strands as described above with reference to FIG. 6 and these
discrete pieces of fastener filament strands may be formed into a
nonwoven web material by forming methods as are known in the art
for example by wet laying and dry laying processes. Exemplary
nonwoven forming methods include air laying, carding, and wet
laying. Briefly, in an air forming or air-laying process fibers
having typical lengths ranging from about 3 to about 50 millimeters
(mm) or longer are separated and entrained in an air supply or air
stream and then deposited onto a forming screen or other foraminous
forming surface, usually with the assistance of a vacuum supply, in
order to form a dry-laid fiber web. Equipment for producing
air-laid webs includes the Rando-Weber airformer machine available
from Rando Corporation of New York and the Dan-Web rotary screen
air former machine available from Dan-Web Forming of Risskov,
Denmark. Carding processes are known to those skilled in the art
and are further described, for example, in U.S. Pat. No. 4,488,928
to Alikhan and Schmidt, and involve starting with staple-length
fibers in a batt that is combed or otherwise treated to provide a
web of generally uniform basis weight. Wet laying processes as are
known in the art involve suspending fibers in a liquid slurry,
depositing the slurry on a screen or other foraminous forming
surface and then removing the excess liquid.
[0090] The nonwoven web material may desirably further comprise
other filaments or fibers such as thermoplastic staple fibers
and/or cellulosic fibers. Staple fibers are well known in the art
and may be monocomponent or multicomponent fibers, and may be
crimped or uncrimped. Cellulosic fibers include those comprising at
least 50 percent by weight cellulose or a cellulose derivative, and
may include cotton, fibers from woody stalks, such as jute, flax,
kenaf, and cannabis, typical wood pulps and derivatives, non-woody
cellulosic fibers, cellulose acetate, cellulose triacetate, rayon,
milkweed, or bacterial cellulose. After the discrete fastener
filament strands and/or other fibers have been formed into a
nonwoven web material, the web may be bonded by methods as are
known in the art such as by thermal point bonding, ultrasonic
bonding, adhesive bonding, through air bonding, and entanglement
bonding including mechanical needling and hydroentangling.
[0091] Nonwoven web materials and laminates of nonwoven webs with
other webs or film materials find a wide variety of use in
disposable and durable goods such as personal care garments and
protective garments. Examples of personal care products include,
but are not limited to, infant, child and adult personal care
products such as diapers, training pants, swimwear, incontinence
garments and pads, sanitary napkins, wipes and the like, and
protective garments include, but are not limitaed to medical and
health care products such as bandages, surgical drapes, gowns,
headwear and footwear, examination gowns, and protective workwear
garments such as coveralls and lab coats.
[0092] Referring to FIGS. 7 and 7A, a device for forming a fastener
product is shown having parallel workstations 60 and 62 and a
weaving device 64. Subsequent to forming the sheet-form array of
fastener elements 18 and splitting the sheet into at least two
elongated fastener filaments 22, each of the elongated fastener
filaments 68 are sent to parallel workstations 60 and 62 for
further processing. Parallel workstations 60 and 62 both comprise
twisting machines 70. The fastener filaments 22 are twisted by the
twisting machines 70 (twisting may include heating the fastener
filaments as described above), then the twisted fastener filaments
26 are each directed to a weaving device 64, which weaves fastener
filaments into a woven fastener material 74. The woven fastener
material 74 may then be directed to a storage roll, for example,
for storage. Untwisted fastener filaments 22 can also be woven by
omitting the twisting operation (see FIG. 7B).
[0093] It should be noted that each parallel workstation 60 and 62
may comprise a different operation. For example, workstation 60 may
comprise a twisting machine and a storage roll and workstation 62
may comprise a chopping machine, a substrate roll, and a storage
roll. Additionally, more than two parallel workstations may be
utilized having workstations comprising various processes. For
example, the sheet-form array of fastener elements may be split
into a number of elongated fastener filaments and each of the
fastener filaments may be directed to a different parallel
workstation.
[0094] As an alternative to weaving, the weaving device can be
replaced by a winding device (not shown) to wind at least two
twisted or untwisted or a combination of twisted and untwisted
fastener filaments together to form a yarn 130 having fastener
elements extending outwardly in multiple radial directions (see
FIG. 16). The filaments can be heated or unheated prior to winding.
If heated, the yarn can be cooled to set the wound form. The yam
can then be further processed. For example, the yarn can be woven,
cut, chopped, deposited on a substrate, or the like, as
examples.
[0095] FIG. 8 shows a storage roll 80 having a roll of an untwisted
fastener filament 22. At least a portion of the fastener filament
22 is removed from the roll 80 and then heated by heater 85. The
heated fastener filament 82 is directed to a twisting device 86
where the filament 82 is twisted into the twisted filament 26. The
twisted filament 26 may then be sent to a workstation for further
processing or directed directly to a storage roll, for example.
[0096] FIGS. 9A-10B are images of twisted fastener filaments formed
by methods similar to those illustrated in FIGS. 1 and 2. Referring
first to FIGS. 9A and 9B, a fastener filament 90 is shown having a
twisted outer surface and a plurality of fastener elements 92
extending radially in multiple directions from the surface of the
fastener product 90. Fastener elements 92 comprise hooks 94 with
heads 96 extending in various directions to create a twisted
fastener product having a plurality of fastening angles.
[0097] Similarly, referring to FIGS. 10A and 10B, a fastener
filament 100 is shown having fastener elements 102 extending
radially in multiple directions from a surface of the fastener
product 100. Fastener elements 102 have mushroom-shaped heads 104
that overhang the twisted surface of the fastener product 100, also
creating a twisted fastener filament having a plurality of
fastening angles.
[0098] Referring to FIG. 11, another method for forming a fastener
product 110 having multiple angles of engagement is shown. A formed
fastener filament 37 is directed to a rod 111 formed of extruded
material, such as resin. The rod of resin is rotated while it
advances such that as the fastener filament is brought into contact
with the rod 110, it is wrapped about the peripheral surface of the
rod in a continuous process of wrapping and advancing. The rod can
also be a discrete length. Also, the filament 37 can cycle about
the rod while the rod advances and/or rotates or is stationary. The
filament can similarly advance. To affix the filament 37 to the
surface of the rod, the rod can be heated to heat bond the filament
to the surface. Other methods of attaching the filament can also be
used such as adhesives, mechanical fasteners, or the like.
[0099] The rod can be of any cross-sectional shape and can be
formed of any material including polymers, metals, foams, etc. The
rod can also be electrically conductive. Where the rod is
electrically conductive, the rod or conductive wire can be
electrically isolated by an insulator prior to wrapping the
fastener filament about the wire. Similarly, the filament 37 can be
wrapped about tubular members 112 of any cross-sectional shape to
form a fastener product having a conduit 114 extending therethrough
(see FIGS. 12 and 12A).
[0100] Referring now to FIGS. 13 and 13A, an illustration of a
section of a twisted fastener filament 26 is shown. Fastener
filament 26 includes fastener elements 18 extending from a twisted
surface 114. Referring particularly to FIG. 13A, fastener filament
26 has a core 116 with a twisted outer surface 114.
[0101] FIGS. 14-15 illustrate various fastener product embodiments.
FIG. 14 shows a woven fastener product 74 comprising woven, twisted
fastener filaments 26. The woven fastener product 74 has fastener
elements 18 extending in multiple directions from the surface of
each twisted fastener filament 26. While woven fastener product 74
consists of only twisted fastener filaments 26, it should be noted
that woven product 74 can be comprised of twisted or untwisted
fastener filaments and/or non-fastener filaments such as string,
yarn, or other fibers, for example.
[0102] Referring now to FIG. 15, a fastener product is shown having
a twisted fastener filament 26 with hooks 18 extending in multiple
radial directions from a twisted outer surface of the filament 26
and a substrate 40 comprising loop material 138 sized to engage
hooks 18. Because hooks 18 extend in multiple radial directions
from the twisted surface of fastener filament 26, some hooks 18 do
not engage loops 138 of substrate 40. Unengaged hooks 18 are
available to engage a different substrate containing, for example,
loops, woven fibers, and/or non-woven fibers. Unengaged hooks 18
may also engage loops 138 of substrate 40 thereby forming a
self-engageable fastener product. Hooks 18 may also be sized to
engage substrate 40, or a like material, to a greater extent
relative to a second material (not shown). This aspect reduces the
probability of unintentional removal of the filaments 26 from the
substrate 40. While FIG. 15 shows substrate 40 comprising loops,
substrate 40 can also be a non-woven, woven fibers, or any other
engageable material.
[0103] A number of embodiments of the invention have been
described. Nevertheless, it will be understood that various
modifications may be made without departing from the spirit and
scope of the invention. For example, the fastener elements may be
J-shaped, T-shaped, palm trees, multi-facing, flat heads,
mushrooms, etc. Additionally, as an alternative to cooling the
heated fastener filament to set the reoriented fastener elements
and/or stems, the twisted and/or wound filaments can be attached or
bonded to, for example, a substrate. This attaching or bonding can
be by for example, staking, melt bonding, adhereing, etc., end
portions of the filament to the substrate. Accordingly, other
embodiments are within the scope of the following claims.
* * * * *