U.S. patent application number 11/043339 was filed with the patent office on 2005-07-28 for molded surface fastener and cushion body formed integrally with the molded surface fastener.
Invention is credited to Akeno, Mitsuru, Gonda, Eiji, Minato, Tsuyoshi.
Application Number | 20050160534 11/043339 |
Document ID | / |
Family ID | 34214301 |
Filed Date | 2005-07-28 |
United States Patent
Application |
20050160534 |
Kind Code |
A1 |
Akeno, Mitsuru ; et
al. |
July 28, 2005 |
Molded surface fastener and cushion body formed integrally with the
molded surface fastener
Abstract
The invention provides a molded surface fastener and a cushion
body formed integrally with it wherein a molded surface fastener
has first resin invasion preventing means of an expandable resin
material for molding a cushion body on each of right and left side
edge portions along a longitudinal direction of a
thermoplastic-resin base member surface, a number of engaging
elements provided between the invasion preventing means, and second
resin invasion preventing means for sectioning the engaging
elements into desired number of regions along the longitudinal
direction of the base member and extending in a width direction
between adjacent sectioned regions, the second resin invasion
preventing means comprising a function for engaging/disengaging a
mating engaging element, thereby the molded surface fastener
securing a required binding force.
Inventors: |
Akeno, Mitsuru; (Toyama-ken,
JP) ; Minato, Tsuyoshi; (Toyama-ken, JP) ;
Gonda, Eiji; (Toyama-ken, JP) |
Correspondence
Address: |
Michael S. Leonard
Everest Intellectual Property Law Group
P.O. Box 708
Northbrook
IL
60065
US
|
Family ID: |
34214301 |
Appl. No.: |
11/043339 |
Filed: |
January 26, 2005 |
Current U.S.
Class: |
5/652 ; 24/452;
5/653 |
Current CPC
Class: |
A44B 18/0076 20130101;
Y10T 24/2792 20150115 |
Class at
Publication: |
005/652 ;
024/452; 005/653 |
International
Class: |
A44B 018/00; A47G
009/00 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 28, 2004 |
JP |
2004-19693 |
Claims
What is claimed is:
1. A molded surface fastener comprising first resin invasion
preventing means for an expandable resin material used for molding
a cushion body on right and left side edge portions along a
longitudinal direction of a surface of a base member of
thermoplastic resin in a flat shape, a number of engaging elements
provided between a right first resin invasion preventing means and
a left first resin invasion preventing means, and second resin
invasion preventing means for sectioning the engaging elements into
a desired number of regions along the longitudinal direction of the
base member, the second resin invasion preventing means extending
in a width direction of the base member between adjacent sectioned
regions and comprising engaging elements, the molded surface
fastener being integrated with the cushion body at a same time when
the cushion body is molded.
2. The molded surface fastener according to claim 1, wherein the
second resin invasion preventing means comprises a lateral wall
portion extending continuously in a width direction of a base
member surface, and the lateral wall portion has a lateral wall and
a plurality of engaging heads extending in back and forth
directions from front and rear wall surfaces of the lateral
wall.
3. The molded surface fastener according to claim 2, wherein a
height of the lateral wall from the base member surface is larger
than a height of a vertex of each of the engaging heads extending
from the lateral wall.
4. The molded surface fastener according to claim 2, wherein a
height of a vertex of each of the engaging heads formed on the
lateral wall from the base member surface is substantially equal to
a height of a vertex of an engaging head of an engaging element
formed in a sectioned region from the base member surface.
5. The molded surface fastener according to claim 2, wherein the
engaging heads extending in the back and forth directions of the
lateral wall so as to adjoin each other in the width direction of
the base member surface extend backward and forward alternately
along the width direction.
6. The molded surface fastener according to claim 1, wherein the
engaging elements formed in a sectioned region and arranged in line
in the width direction of the base member are joined together
successively through at least partial side surfaces of rising
portions thereof.
7. The molded surface fastener according to claim 1, wherein the
first resin invasion preventing means formed on the right and left
side edge portions along the longitudinal direction of the base
member surface comprises two or more rows of longitudinal wall
portions arranged in line with an interval in the width direction
of the base member, and the interval formed between the
longitudinal wall portions on adjacent rows is formed as an aisle
having a predetermined length in a passage direction of an
expandable resin.
8. The molded surface fastener according to claim 7, wherein
respective wall portions of two or more row of the longitudinal
wall portions are divided at a predetermined pitch in the
longitudinal direction of the base member by gaps, and the gaps
between division wall portions adjoining in a row direction are
arranged in a houndstooth shape between the rows.
9. The molded surface fastener according to any one of claims 7 and
8, wherein a first wall portion of two or more rows of the
longitudinal wall portions is disposed adjacent to sectioned
engaging elements, a height of the first wall portion from the base
member surface is substantially equal to a height of a lateral wall
portion which is a second resin invasion preventing means from the
base member surface, and heights of part of the longitudinal wall
portion and a division wall piece disposed outside the first wall
portion are set less than the height of the first wall portion.
10. The molded surface fastener according to claim 1, wherein the
molded surface fastener comprises a magnetic body or a magnet.
11. The molded surface fastener according to claim 10, wherein the
magnetic body is buried in a base member so as to extend
continuously in a longitudinal direction of the base member.
12. The molded surface fastener according to claim 10, wherein the
magnet is buried in a base member so as to extend continuously in a
longitudinal direction of the base member.
13. A cushion body formed integrally with the molded surface
fastener according to any one of claims 10 and 11.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a surface fastener having
male engaging elements composed of plural hook pieces which engage
mating loop-like female engaging elements on one surface of its
flat base member and invasion preventing means at least along right
and left side edge portions in a longitudinal direction of the base
member for blocking an invasion of a molding resin material into an
engaging-element forming region when this product is molded.
[0003] 2. Description of Related Art
[0004] Passenger seats of automobiles or trains, and various kinds
of sofas and office chairs have a cushion body inside their surface
skin materials. As this cushion body, so-called rock wool, which is
obtained by entangling stiff fibers such as palm fibers and flax or
synthetic fibers and hardening with rubber or the like, or molded
bodies made of various kinds of expandable resin materials are
used. These cushion materials have a curved face composed of convex
and concave shapes satisfying human engineering factors in order to
maintain a seating posture which provides no fatigue despite a
long-hour seating. If it is intended to effectively manufacture the
cushion materials having such a complicated surface shape in large
quantities considering its cushion performance, the aforementioned
rock wool that requires a number of manufacturing processes cannot
meet the demand. Contrary to this, cushion bodies of expanded resin
have been used widely because it can be manufactured in a single
process and diversified shapes can be obtained easily. That is, the
cushion body of expandable resin is molded into a desired shape at
a same time when an expansion is induced by pouring an expandable
resin material such as expandable urethane resin into a mold.
[0005] Various kinds of fiber cloth or natural or synthetic leather
surface skin material are applied to and integrated with the
surface of the cushion body formed in this way. For this
integration, there is employed means in which an expandable resin
material is poured into a mold with a surface skin material
adsorbed along a mold surface so as to integrate a cushion body
with a rear surface of the surface skin material at a same time as
molding is executed, or means in which, after the cushion body is
formed of an expandable resin material with a mold, the surface
skin material is applied to its surface and fixed thereto.
[0006] According to an above method of an integral molding, when
the surface skin material is set along an inner surface of the
mold, it is adsorbed by means of adsorption means. When the surface
skin material is deformed following a surface of a cushion body
having a complicated configuration, the surface skin material needs
to be itself of material having an excellent potential to be
stretched. However, because there is a limit to be stretched
depending on a material, many wrinkles are likely to occur
particularly between a seating surface and a peripheral side
surface and up to now, great efforts have been made to remedy this
phenomenon.
[0007] Further, since this integral molding integrates the cushion
body and the surface skin material throughout their entire
surfaces, if, for example, a strong force is applied in a direction
in which the surface skin material deflects on the surface of the
cushion body during actual usage, a shearing force is generated
between the surface skin material and the cushion body, the cushion
body is often partially torn and then, the surface skin material is
separated. The material to be used as the surface skin material is
automatically limited in order to exclude an occurrence of such
wrinkles, and it is preferable to allow a slight motion between the
surface skin material and the cushion body so that any excess force
is not applied between them. For the reason, instead of integrating
the surface skin material at a same time when the cushion body is
molded, a method of applying the surface skin material onto a
cushion body molded preliminarily has become popular.
[0008] As a general method for applying the surface skin material
onto the cushion body made of an expandable resin material, an
engaging-element forming surface of a surface fastener is placed
and fixed on a projecting surface portion on a bottom of a mold
corresponding to a concave surface of a cushion body so that the
engaging-element forming surface is opposed to the projecting
surface portion and then an expandable resin material is poured in
the mold so as to mold the cushion body in an expanded state while
the surface fastener is buried in and integrated with the concave
surface of the cushion body with the engaging elements exposed
outside. At a time of this expansion molding, the expandable resin
material is prevented from flowing into an engaging-element forming
region. The surface skin material made of various kinds of
materials such as pile woven/knit fabric, natural leather and
synthetic leather formed in a shape of a bag corresponding to an
outer shape of the cushion body is applied to the cushion body
molded by the above-mentioned way. Then, female engaging elements
disposed on a rear surface of the surface skin material are pressed
against the engaging-element forming surface of the surface
fastener integrated with the cushion body so that the surface skin
material is bonded and fixed along the concave surface of the
cushion body and prevented from rising from the cushion body.
[0009] To prevent the expandable resin material from invading into
the engaging-element forming region of the surface fastener when
the cushion body is molded, expandable resin material invasion
preventing walls 104, 105 are usually provided integrally along a
periphery of a base member 102 of a surface fastener 101 so as to
surround a number of engaging elements 103 as disclosed in, for
example, U.S. Pat. Nos. 5,061,540 and 5,766,723 and as shown in
FIGS. 13 and 14. Same designations and similar reference numerals
are attached to corresponding designations and reference
numerals.
[0010] On the other hand, recently, the surface fastener has been
formed continuously in a form of a tape. Even in this case,
longitudinal invasion preventing walls are formed integrally along
right and left side edge portions in a width direction of a surface
fastener so that a number of engaging elements formed on a single
side of a flat base member are surrounded from right and left sides
in the same way as in the U.S. Pat. No. 5,766,723. Consequently,
invasion of an expandable resin material is prevented from invading
into an engaging-element forming region from a lateral (width)
direction, and additionally, the engaging-element forming region is
sectioned along a longitudinal direction and a second invasion
preventing wall is formed between adjoining sections so that it
extends in the width direction so as to prevent the expandable
resin material from invading from a length (longitudinal) direction
of the surface fastener. A height of the invasion preventing walls
for the expandable resin material is set larger than a height of
the surrounded engaging elements.
[0011] When the cushion body is molded, as described above, the
surface fastener is placed such that its engaging-element forming
surface is directed to the projecting surface portion on the bottom
of the mold and fixed thereto and then, the expandable resin
material is poured into the mold. When the expandable resin
material is poured, invasion of the expandable resin material is
blocked by the invasion preventing wall erected for surrounding the
engaging elements in each section and as a consequence, the
expandable resin material is prevented from invading into the
engaging-element forming region. The surface fastener to be
integrated with the cushion body by molding is bonded to and
integrated with the cushion body through the rear surface of its
base member and an outer wall surface of the invasion preventing
wall. Consequently, no expandable resin invades into the
engaging-element forming region and thus, a bonding function of the
surface fastener is exerted securely. To secure a bonding strength
between the cushion body and the surface fastener, when the surface
fastener is molded, its rear surface is formed into an uneven
surface or unwoven fabric is integrated with the rear surface.
[0012] To place and securely fix the engaging elements at a
predetermined place of the projecting surface portion on the bottom
of the mold, a permanent magnet is usually provided on the base
member of the surface fastener or a permanent magnet 108 is buried
in a portion of the mold corresponding to a surface-fastener
placing portion while a magnet body 109 is provided on the base
member of the surface fastener as in the U.S. Pat. No. 5,766,723.
Consequently, the surface fastener 101 is positioned and fixed
accurately at a placing position of the surface fastener 101 by
using a magnetic attraction force of the magnet 108. The permanent
magnet or magnetic body is usually formed in a form of a tape,
linear shape or stripe, and a material that is excellent in
plasticity such as synthetic resin mixed with a ferrite magnet or
magnetic powder is used. As the magnetic body, a thin tape material
or wire made of steel is used and this material is buried in the
base member at the same time when the surface fastener is
molded.
[0013] As described above, the longitudinal invasion preventing
walls of the expandable resin material of the surface fastener
disclosed in the U.S. Pat. Nos. 5,061,540 and 5,766,723 are formed
continuously along both side edge portions in a width direction of
the engaging-element forming surface of the base member and a
lateral invasion preventing wall is provided to section every
predetermined number of engaging elements formed in the
engaging-element forming surface of the base member along the
longitudinal direction of the base member, so that it is formed
between adjoining sections. This lateral invasion preventing wall
is not always limited to one but two lateral invasion preventing
walls may be formed in parallel. Due to the existence of the
longitudinal and lateral invasion preventing walls, invasion of the
expandable resin material from the longitudinal and lateral
directions is blocked when the cushion body is expansion-molded. As
a result, the invasion into the engaging-element forming region is
completely blocked.
[0014] As described, in recent years, generally a number of
engaging elements and the invasion preventing walls have been
formed integrally and continuously on the surface of a tape-like
base member by injecting or extruding continuously molten resin to
a peripheral surface of a die wheel comprising cavities for molding
a number of engaging elements and expandable resin material
invasion preventing walls, the die wheel being rotated in a single
direction. However, even if a molded surface fastener obtained by
this way is long, because an interval of the lateral invasion
preventing walls is determined depending on an outer diameter of
the die wheel, a specified pattern of the interval repeats.
[0015] On the other hand, for example, in a passenger seat of an
automobile, an uneven surface composed of an appropriate curved
surface is formed on a surface of the seat in order to secure a
seating posture thought to be most favorable from human engineering
viewpoints. A configuration of this uneven surface, particularly a
length thereof is not constant but varies. The molded surface
fastener is integrated with a cushion body along the concave
surface portion of a seating surface of the cushion body having the
uneven surface. When covering the cushion body with the surface
skin material, by joining a female fastener region comprising the
female engaging elements on the rear surface of the surface skin
material with the engaging-element forming region of the surface
fastener under a pressure, the surface skin material is mounted on
the cushion body such that it is tightly stretched.
[0016] If it is intended to mount a tape-like molded surface
fastener molded continuously by the above-mentioned way
corresponding to a length of the concave surface portion of the
cushion body which is different in length, the long molded surface
fastener needs to be cut out to a predetermined length before use.
Since a cutting position at this time is determined depending on
the length of the concave surface portion, a cutting length is not
always same. Consequently, the surface fastener often has to be cut
out within the engaging-element forming region in a section
partitioned by the lateral invasion preventing wall with a
predetermined number of engaging elements. If the surface fastener
is cut out within the engaging-element forming region, the
expandable resin material invades into a cut engaging-element
forming region and thus, the engaging elements in the region are
buried in the expandable resin. Thus, the engaging elements in the
region in which the expandable resin material invades loses its
function as engaging elements and as a consequence, a binding force
originally demanded as a surface fastener cut into a predetermined
length cannot be secured.
[0017] Particularly, in conventional surface fasteners disclosed in
the above-described U.S. Pat. Nos. 5,061,540 and 5,766,723,
intervals between the lateral invasion preventing wall formed in
adjacent sections and adjoining engaging elements interposing the
lateral invasion preventing wall is usually equal to an interval
between the engaging elements formed in the engaging-element
forming region. Further, since no engaging element exists in these
intervals and the lateral invasion preventing wall is thick, no
binding force is exerted. As a result, it becomes more difficult to
obtain a desired binding force.
SUMMARY OF THE INVENTION
[0018] Accordingly, the present invention has been achieved to
solve these problems and an object of the present invention is to
provide a tape-like continuously molded surface fastener capable of
suppressing an invasion of an expandable resin material into an
engaging-element forming region to its minimum extent even if it is
cut at an arbitrary position in a longitudinal direction so as to
secure an absolutely necessary binding force.
[0019] The above-mentioned object is achieved by a molded surface
fastener comprising first resin invasion preventing means for an
expandable resin material used for molding a cushion body, the
first resin invasion preventing means provided on right and left
side edge portions along a longitudinal direction of a surface of a
base member of thermoplastic resin in a flat shape, a number of
engaging elements provided between a right first resin invasion
preventing means and a left first resin invasion preventing means,
and second resin invasion preventing means for sectioning the
engaging elements into a desired number of regions along the
longitudinal direction of the base member, the second invasion
preventing means extending in a width direction of the base member
between adjacent sectioned regions and comprising engaging
elements, the molded surface fastener being integrated with the
cushion body at a same time when the cushion body is molded.
[0020] More specifically, the second resin invasion preventing
means comprises a lateral wall portion extending continuously in
the width direction of the base member surface and plural engaging
heads provided on a top portion of the lateral wall portion and
extending backward and forward from a front and rear wall surfaces
in the longitudinal direction of the base member.
[0021] Preferably, a height of the lateral wall from the base
member surface is larger than a height of a vertex of each of the
engaging heads extending from the lateral wall, and the height of
the vertex of the engaging head formed on the lateral wall from the
base member surface is substantially equal to the height of the
vertex of an engaging head of an engaging element formed in a
sectioned region from the base member surface.
[0022] In addition, it is desired that the engaging heads extending
in the back and forth directions of the lateral wall so as to
adjoin each other in the width direction of a surface of the base
member in the flat shape extend backward or forward alternately
along the width direction, and further it is preferable that the
engaging elements formed in the sectioned region and arranged in
line in the width direction of the base member are joined together
successively through at least partial side surfaces of rising
portions thereof.
[0023] According to the present invention, the first resin invasion
preventing means formed on the right and left side edge portions
along the longitudinal direction of the base member surface
comprises two or more rows of longitudinal wall portions arranged
in line with an interval in the width direction of the base member,
and the interval formed between the longitudinal wall portions on
adjacent rows is formed as an aisle having a predetermined length
in a passage direction of the expandable resin. Then, preferably,
respective wall portions of two or more rows of the longitudinal
wall portions are divided at a predetermined pitch in the
longitudinal direction of the base member by gaps, and the gaps
between the respective wall portions adjoining in a row direction
are arranged in a houndstooth shape.
[0024] Further, preferably, a first wall portion of two or more
rows of the longitudinal wall portions is disposed adjacent to the
sectioned engaging elements, a height of the first wall portion
from the base member surface is substantially equal to a height of
the lateral wall portion which is the second resin invasion
preventing means from the base member surface, and a height of part
of a longitudinal wall portion disposed outside the first wall
portion is set equal to or less than the height of the first wall
portion. The molded surface fastener having such a structure is
preferably integrated with the cushion body of an automobile seat,
a sofa and an office chair in particular.
[0025] The molded surface fastener of the invention is preferred to
comprise a magnetic body or a magnet. As a preferred embodiment, a
magnetic body or a magnet is buried in the base member so as to
extend continuously in the longitudinal direction of the base
member. The present invention is not restricted to such an
embodiment, but it is permissible to mix a composition resin
material of the molded surface fastener with a magnetic body or
power material composed of a magnetic body or it is permissible to
mix the resin material with a magnetic body or power material
composed of a magnetic body and coat an exposed portion of the
molded surface fastener with this.
[0026] Since the second resin invasion preventing means of the
present invention comprises the engaging elements, reduction in
binding force due to an existence of the lateral invasion
preventing wall which can be seen in a prior art can be
eliminated.
[0027] Because the second resin invasion preventing means comprises
the lateral wall portion extending continuously in the width
direction of the base member surface and plural engaging heads
provided on the top portion of the lateral wall portion and
extending backward or forward from the front and rear wall surfaces
in the longitudinal direction of the base member, the lateral wall
portion blocks the invasion of the expandable resin into the
engaging-element forming region and the engaging heads having a
same configuration as those of the engaging elements formed in the
engaging-element forming region is bound with female engaging
elements on a rear surface of a surface skin material.
Consequently, a required binding force is secured by complementing
a bonded portion that does not conventionally exist.
[0028] If the height of the lateral wall portion from the base
member surface is set larger than the height of a highest vertex of
the engaging elements extending from the lateral wall portion while
the height of the vertex of plural engaging heads formed on the
lateral wall portion from the base member surface is set
substantially equal to the height of the vertex of the engaging
heads of engaging elements formed in the sectioned region from the
base member surface, the expandable resin trying to invade into the
engaging-element forming region adjoining across the lateral wall
portion can be blocked securely by the lateral wall portion. At a
same time, the engaging elements extending from the lateral wall
portion also engage the female engaging elements provided on the
rear surface of the surface skin material with a same engagement
ratio as engaging elements formed in other sectioned regions.
[0029] If the engaging heads adjoining in the width direction of
the base member surface extending backward and forward of the
lateral wall portion are extended backward and forward alternately
with respect to the width direction, directions of engagements with
mating female engaging elements in the lateral wall portion are of
two directions, i.e. forward and backward. AS a result, an
engagement ratio is increased correspondingly and at a same time,
an engagement force is also improved. Further, if at least partial
side surfaces of rising portions of the engaging elements formed in
the sectioned region and aligned in the width direction of the base
member are combined successively, the respective engaging elements
can be prevented from falling down in a lateral direction
effectively.
[0030] The first resin invasion preventing means formed on the
right and left side edge portions along the longitudinal direction
of the base member surface comprises two or more rows of
longitudinal wall portions arranged in line with the interval along
the width direction of the base member and the interval formed
between the respective longitudinal wall portions of adjoining rows
is formed as an aisle having a predetermined length in the passage
direction of the expandable resin. In this case, each wall portion
of each of two or more rows of longitudinal wall portions is
divided by the gaps at a specified pitch in the longitudinal
direction of the base member and gaps between the respective
division wall portions adjoining in the row direction are arranged
in the houndstooth shape. As a result, the expandable resin
material invades through intervals formed between the respective
rows and the gaps between the division wall portions in the
longitudinal wall portion, and it is combined and integrated with
the division wall portions so as to engulf each division wall
portion. Consequently, because the cushion body and the molded
surface fastener are bonded through the rear surface and an
external wall portion of the longitudinal wall portion, and further
they are bonded so as to surround the respective division wall
portions of each row, the binding strength between the cushion body
and the molded surface fastener is improved.
[0031] In the case of that the first wall portion of two or more
rows of the longitudinal wall portions is disposed adjacent to the
sectioned engaging elements, the height of the first wall portion
from the base member surface is substantially equal to the height
of the lateral wall portion which is the second resin invasion
preventing means from the base member surface, and the height of
part of the longitudinal wall portion disposed outside the first
wall portion is set less than the height of the first wall portion,
a low longitudinal wall portion is surpassed by the invading
expandable resin material and covered by and integrated with the
expandable resin material, thereby improving the binding strength
between the cushion body and the molded surface fastener.
[0032] If the magnetic body or the magnet extending continuously in
the longitudinal direction is buried in and integrated with the
base member, the molded surface fastener can be placed and fixed
accurately at a surface-fastener setting position in the mold for
the cushion body using a magnetic attracting action. The magnetic
body or magnet can be integrated with the molded surface fastener
easily by introducing a linear or tape-like magnetic body or magnet
in a peripheral direction at a portion of a die wheel in which the
base member is to be formed when the molded surface fastener is
continuously molded. If the base member of the molded surface
fastener is thin, the linear or tape-like magnetic body or magnet
is more likely to be separated from the base member. However, a
thickness of the base member at a portion with which the magnetic
body or magnet is integrated is increased, or the longitudinal wall
portion is erected on the portion, the magnetic body or magnet is
buried completely in the base member so that a possibility of a
separation is eliminated. If the magnet is buried in the mold, it
is permissible to mix magnetic powder composed of alloy such as
iron, cobalt, nickel or the like in at least part of the base
member, the engaging elements and the longitudinal wall
portion.
[0033] When the molded surface fastener is placed on a surface of
the mold for molding the cushion body, the molded surface fastener
can be positioned and fixed accurately in the mold by a magnetic
attracting action between the magnet or magnetic body provided in
the molded surface fastener and the magnet provided in the mold.
Additionally, the molded surface fastener is prevented from moving
from its position when the expandable resin material expands and
any gap is prevented from being generated between the longitudinal
wall portion and the lateral wall portion and the surface of the
mold.
[0034] The cushion body integrated with the molded surface fastener
of this kind can secure a specified binding force with respect to
the surface skin material and respond to a slight deflection.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] FIG. 1 is a top view partially showing a molded surface
fastener according to a first embodiment of the present
invention;
[0036] FIGS. 2 and 3 are sectional view seen in directions of
arrows along the lines II-II and III-III in FIG. 1;
[0037] FIGS. 4 to 8 are sectional view seen in directions of arrows
along the lines IV-IV to IIX-IIX in FIG. 1;
[0038] FIG. 9 is a top view partially showing a molded surface
fastener according to a second embodiment of the present
invention;
[0039] FIGS. 10 and 11 are sectional view seen in directions of
arrows along the lines X-X and XI-XI in FIG. 9;
[0040] FIG. 12 is a sectional view seen in a direction of an arrow
along the line XII-XII in FIG. 9;
[0041] FIG. 13 is a partial perspective view showing an example of
a surface fastener integrated with a conventional cushion body;
and
[0042] FIG. 14 is a partial sectional view at a time of expansion
molding showing another example of the surface fastener integrated
with a conventional cushion body.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0043] Hereinafter, embodiments of the present invention will be
described specifically with reference to the accompanying drawings.
FIGS. 1 to 8 show a first embodiment of the present invention.
[0044] As shown in FIG. 1, a number of engaging elements 3 in a
hook-like shape are formed in an engaging-element forming region
except both side edge portions on one surface of a base member 2 in
a flat shape of a molded surface fastener 1 in a tape-like shape of
this embodiment, and three rows of longitudinal wall portions 4 are
erected as first resin invasion preventing means of the present
invention on both side edge portions of the base member 2 along a
longitudinal direction such that they are arranged linearly in
parallel. As shown in FIGS. 1-3, 6 and 8, these longitudinal wall
portions 4 are constituted of a number of division wall portions 5
divided at a predetermined pitch along the longitudinal direction.
The three rows of the longitudinal wall portions 4 are deflected
about half a pitch in terms of their division positions and gaps
formed between the division wall portions 5 in the longitudinal
direction are arranged in a houndstooth shape between adjoining
rows. According to this embodiment, as shown in FIGS. 1-3 and 7,
division wall pieces 6 having a lower height are disposed in the
longitudinal direction as the first resin invasion preventing means
of the present invention in each interval between the rows of the
longitudinal wall portions 4 arranged in three rows.
[0045] The interval formed between the rows of the longitudinal
wall portions 4 and the gaps formed between the adjacent division
wall portions 5 serve as aisles for an expandable resin material
poured into a mold (not shown) at a time of molding of a cushion.
The expandable resin material gradually invades through the gaps
and intervals from a width direction of the molded surface fastener
1 around each division wall portion 5 toward the engaging-element
forming region. Before it reaches a first longitudinal wall portion
4a nearest the engaging-element forming region, it hardens in an
expanded state and does not reach the engaging-element forming
region. As a result, it bonded and fixed in such a manner that it
surrounds all the division wall portions 5. At this time, because
the division wall pieces 6 are lower than the division wall
portions 5, the expandable resin material invading into the
longitudinal wall portions 4 surpasses the division wall pieces 6
and then invades into the interval formed inside the division wall
pieces 6 between the longitudinal wall portions 4. As a
consequence, the division wall pieces 6 are buried in the
expandable resin material. Consequently, the division wall pieces 6
are buried in the cushion body, so that fixing strength between the
molded surface fastener 1 and a cushion body (not shown) is
increased by a so-called anchor effect.
[0046] A number of the engaging elements 3 formed in the
engaging-element forming region are erected in plural lines across
the width direction of the base member 2. As shown in FIG. 1, three
rows thereof are defined as a section by a lateral wall portion 7
which is a feature portion of the present invention. As shown in
FIGS. 1 and 5, each of the engaging elements 3 comprises a rising
portion 3a which rises upward and an engaging head 3b which is
extended in the longitudinal direction of the base member 2 while
its front end is curved downward from a top end of the rising
portion 3a, thereby entirely forming a hook-like configuration. In
this embodiment, as shown in FIGS. 1 and 5, two engaging elements 3
adjacent in the width direction of the base member 2 have engaging
heads 3b which extend in opposite directions, back and forth along
the longitudinal direction. A pair of these engaging elements 3 is
integrated through side surfaces of the rising portions 3a having a
same shape. Six pairs of the engaging elements 3 are erected in
line in the width direction of the base member 2. Of course, the
shape of the engaging elements 3 are not restricted to an indicated
example and further, a number of the engaging elements arranged in
line is not restricted to the indicated example.
[0047] In the lateral wall portion 7 which is the feature of the
present invention, as shown in FIGS. 1, 4 and 5, a lateral wall 7a
extends linearly across the base member 2 between the longitudinal
wall portions 4 erected on both side edge portions in the width
direction of the base member 2. A height of the lateral wall 7a
from a base member surface is equal to a height of the longitudinal
wall portions 4, and a maximum height of the longitudinal wall
portions 4 and the lateral wall 7a is set slightly larger than a
height of a vertex of the engaging head 3b of the engaging element
3. Part of a rising portions 8a of engaging elements 8 having a
same shape as the above-described pair of engaging elements 3, and
whole engaging heads 8b are integrally attached to front and rear
wall surfaces of the lateral wall 7a in the longitudinal direction
of the base member such that front ends of the respective engaging
heads 8b are directed alternately in opposite directions in the
back and forth direction. A height of the engaging heads 8b are
equal to the height of the engaging heads 3b of the aforementioned
engaging elements 3 formed in the engaging-element forming
region.
[0048] According to this embodiment, three linear magnetic bodies 9
are fused integrally with side edge portions in the width direction
of the base member 2 and the engaging-element forming surfaces on a
central portion of the base member 2 such that they extend linearly
in the longitudinal direction. As the linear magnetic bodies 9, a
mono-filament of synthetic resin mixed with magnetic powder
composed of an alloy such as iron, cobalt or nickel is used.
Although, according to this embodiment, the aforementioned linear
magnetic bodies 9 are employed assuming that a magnet is placed at
a surface-fastener installation position of a mold for molding the
cushion body, it is permissible to use narrow tape-like metallic
foil instead of a linear body. If no magnet is placed in the mold
for molding the cushion body, a linear or tape-like magnet may be
fixed directly to the base member 2 instead of the magnetic
body.
[0049] If part of the linear magnetic bodies 9 are integrated with
the base member 2 so as to be exposed on a surface of the base
member 2 for securing a base member strength, the linear magnetic
bodies 9 are likely to be separated from the base member 2 if a
slight external force is applied. Thus, according to this
embodiment, regions of the base member 2 with which the linear
magnetic bodies 9 are to be integrated are formed thick in the
longitudinal direction. According to the embodiment, as shown in
FIGS. 2 and 3, thick portions on both side edge portions are formed
within the division wall pieces 6 lower than the longitudinal wall
portions 4 and three rows of the longitudinal wall portions 4 in
the width direction of the base member 2, and one of the thick
portions in a central portion in the width direction of the base
member 2 corresponding to one of the linear magnetic bodies 9 is
provided with two pairs of engaging elements 3. The engaging heads
3b of the two engaging elements 3 disposed outside of these two
pairs of engaging elements 3 are extended in a same direction while
the two engaging elements 3 disposed in a middle are extended in an
opposite direction to the aforementioned engaging elements, and
proximal end portions of the two adjoining engaging elements 3
located in the middle are combined and integrated with a block
piece 10.
[0050] The linear magnetic bodies 9 disposed on both side edge
portions in the width direction of the base member 2 is
respectively surrounded by and integrated with the division wall
portions 5 and the division wall pieces 6 and as a consequence, the
division wall portions 5 and the division wall pieces 6 form the
thick portions of the base member 2 so as to prevent the linear
magnetic bodies 9 from being separated from the base member 2.
Therefore, the division wall portions 5 and the division wall
pieces 6 have a function for blocking an invasion of the expandable
resin material at the time of molding the cushion body and a
function for preventing the linear magnetic bodies 9 from being
separated from the base member 2. On the other hand, a partial
peripheral surface of the linear magnetic body 9 disposed in the
central portion in the width direction of the base member 2 is
surrounded by and integrated with the two pairs of engaging
elements 3 and the block piece 10 connecting the engaging elements
3. As a consequence, the thick portion of the base member 2 is
formed by the two pairs of engaging elements 3 and the block piece
10, thereby preventing the linear magnetic body 9 from being
separated from the base member 2. Since the linear magnetic bodies
9 attached to the base member 2 is attracted by a magnetic
attraction force of the magnet (not shown) attached to the mold
(not shown) for molding the cushion body, the molded surface
fastener 1 in a tape-like shape is positioned and fixed to a
predetermined position accurately and securely.
[0051] In the meantime, the magnetic body does not have to be the
linear shape and may be, for example, a tape-like metallic thin
sheet. Alternatively such magnetic body may be attached separately.
Further, instead of the magnetic body, a magnet may be used. To
attach this magnetic body or magnet to the molded surface fastener
1, it is permissible to form a magnetic film layer on the base
member 2 by coating a rear surface of the base member 2 with
magnetic resin such as a resin adhesive agent or resin paint mixed
with magnetic powder, or form a surface laminate by mixing the
magnetic powder into any one of the base member 2, the engaging
element 3, the longitudinal wall portion 4 and the lateral wall
portion 7, or laminate a resin layer containing the magnetic powder
on a top surface of the lateral wall portion 7. As described above,
these treatments are not restricted to the magnetic body, but the
same treatments are possible for the magnet.
[0052] The molded surface fastener 1 having such a structure of
this embodiment can be manufactured continuously and effectively.
As its basic manufacturing method, for example, a method disclosed
in U.S. Pat. No. 5,620,769 can be employed. Its detailed
description of the aforementioned US patent specification is
omitted here and a manufacturing apparatus and manufacturing method
for the molded surface fastener will be described simply without
any reference of drawings.
[0053] A continuous injection nozzle for molten resin is provided
to oppose a peripheral surface of a die wheel which is rotated in a
single direction. A number of cavities for forming the engaging
elements are formed in a central region of the peripheral surface
of the die wheel, and plural rows of cavities for forming the
division wall portions 5 and the division wall pieces 6 are formed
on both side edge portions in an axial direction of the peripheral
surface such that they extend intermittently. Further, plural
cavities for forming the lateral wall portions 7 are formed in a
region in which the cavities for the engaging elements 3 are to be
formed. The cavities for the lateral wall portions 7 extend in
parallel to a rotation axial line of the die wheel with a
predetermined phase angle in a peripheral direction. On the other
hand, continuous supply portions for the linear magnetic bodies 9
are provided at an upstream side of a peripheral portion of the die
wheel in the rotation direction that is opposing the injection
nozzle. Then, the linear magnetic bodies 9 are supplied
continuously to positions opposing the injection nozzle of the die
wheel from the supply portions. Coolant is supplied inside the die
wheel to always cool the die wheel. Further, the lower half portion
of this die wheel is immersed in a coolant bath disposed below.
[0054] In a continuous manufacturing apparatus of the molded
surface fastener having an above-described structure, a molten
resin material is continuously injected to the peripheral surface
of the die wheel from the continuous injection nozzle. At this
time, the die wheel is rotated in a single direction, and the base
member 2 of the surface fastener is continuously formed of the
molten resin injected on the peripheral surface in a gap between
the injection nozzle and the die wheel. At a same time, the
engaging elements 3, the longitudinal wall portions 4, the division
wall pieces 6 and the lateral wall portions 7 are formed
successively with respective cavities. At this molding time, the
linear magnetic bodies 9 are introduced to injection positions from
the upstream side in the rotation direction of the die wheel
relative to an injection position of the molten resin injected from
the injection nozzle. According to this embodiment, since
substantially 2/3 of each of the linear magnetic bodies 9 is
exposed on the surface of the base member 2, three guide grooves
for three linear magnetic bodies 9 are formed continuously in the
peripheral direction in the peripheral surface of the die wheel in
addition to the above-described cavities.
[0055] Thus, in the surface of the base member 2 of the molded
surface fastener 1 which is in a continuous tape-like shape and
formed in the above-described manner, the surface having the
engaging elements formed thereon, a lower 1/3 of each of the linear
magnetic bodies 9 is buried below the surface of the base member 2,
and a top surface portion of each of the linear magnetic bodies 9
are locally covered with any of the engaging elements 3, the
longitudinal wall portions 4, the division wall pieces 6 and the
lateral wall portions 7. The linear magnetic bodies 9 are
continuously fixed to and integrated with the surface of the base
member 2 at a same time when the molded surface fastener 1 is
molded. The molded surface fastener 1 is supported by the
peripheral surface of the die wheel and carried half a turn with a
rotation of the die wheel. While being carried, it is cooled and
hardened, separated from the peripheral surface of the die wheel by
a take-up roll and then carried to a subsequent winding
process.
[0056] In the indicated example, the rear surface of the
engaging-element forming surface of the base member 2 is formed as
an uneven surface 2a. The reason for this is to increase a bonding
area with respect to an expanded resin so as to intensify a bonding
force. The uneven surface 2a can be formed easily by installing a
pressing roll (not shown) having a lot of unevenness in its
peripheral surface in such a manner that the pressing roll opposes
to the peripheral surface of the die wheel via the molded surface
fastener after molding. Although the pressing roll may be rotated
with a moving of the molded surface fastener, it is better to drive
it synchronously with a rotation speed of the die wheel. Of course,
the rear surface may be formed in flat instead of the uneven
surface 2a.
[0057] To integrate the molded surface fastener 1 of the present
invention manufactured in this way with a cushion body (not shown)
made of the expandable resin material, the molded surface fastener
1 in a long continuous tape-like shape is cut in a desired length,
and a cut piece is placed such that the surface on which the
engaging elements 3 are formed is directed to a projecting surface
portion in a mold (not shown) corresponding to a concave portion in
the cushion body. A magnet (not shown) is buried in the projecting
surface portion of the mold, and if the molded surface fastener 1
is placed on the projecting surface portion, the molded surface
fastener 1 is attracted by an attraction force of the magnet
through the linear magnetic bodies 9 and then, the molded surface
fastener 1 is automatically adsorbed and fixed to the projecting
surface portion with a desired posture.
[0058] An expandable resin material is poured into the mold and
flows from the rear surface to the longitudinal wall portions 4 and
the lateral wall portions 7 of the molded surface fastener 1,
spreading over an entire surface of the mold while an expansion
starts. At this time, the molded surface fastener 1 is positioned
and fixed due to the attraction force of the magnet in the mold and
its position is not moved by a flow and an expandable pressure of
the expandable resin material. Although a fluid expandable resin
material tries to invade into a forming region of the engaging
elements 3 from the width direction of the molded surface fastener
1 through the gaps between the division wall portions 5 of the
longitudinal wall portions 4 composed of plural rows and gaps
between the division wall piece 6 as described above, it is blocked
by the division wall portions 5 and the division wall pieces 6 and
thus, its expansion and hardening are completed before reaching the
engaging-element forming region. On the other hand, as for the
longitudinal direction of the molded surface fastener 1, an
obtained long molded surface fastener 1 needs to be cut to a
predetermined length, as described above. It is desirable if the
lateral wall portion 7 can be cut into two sections in the
longitudinal direction at that time. However, a required length of
the cut piece is not always same. Further, in a surface fastener
formed continuously as described above, the interval between the
lateral wall portions 7 cannot be changed arbitrarily. Therefore,
the molded surface fastener 1 is often cut within the forming
region of the engaging element 3.
[0059] As a result, a remainder region in which only the engaging
elements 3 are formed without any lateral wall portion 7 exists on
a sheared end side of the cut molded surface fastener 1. However,
if the interval between the lateral wall portions 7 is adjusted, it
is possible to prevent affecting the entire length of the cut
molded surface fastener 1. If, after the cut molded surface
fastener 1 is placed and fixed in the mold, the expandable resin
material is poured as described above, the expandable resin
material invades into the reminder region in which the engaging
elements 3 exist through a cut end of the molded surface fastener
and sometimes reaches a nearest lateral wall portion 7. Due to this
invasion, the engaging elements 3 existing in the remainder region
are buried in and integrated with the interior structure of an
expanded body.
[0060] As a result, the engaging elements existing in the remainder
region are favorable because the fixing strength of the molded
surface fastener 1 to the cushion body is intensified by the anchor
effect. The expandable resin material after reaching the lateral
wall portion 7 is prevented from flowing further by the lateral
wall portion 7 and thus, it does not reach the engaging elements
within the engaging-element forming region surrounded by the
longitudinal wall portions 4 and the lateral wall portions 7. The
cushion body after the molded surface fastener 1 is fixed to and
integrated with a desired place is covered with the surface skin
material according to a specified method. By pressing a mounting
portion of the molded surface fastener, the molded surface fastener
engages female engaging elements on a rear surface of the surface
skin material so that the surface skin material do not rise from
the cushion body, thereby being mounted accurately and fittingly
along a curved surface of the cushion body.
[0061] In the present invention, since the lateral wall portion 7
is not a simple wall but has engaging elements 8 in a hook-like
shape on its top surface, there is no region without any engaging
elements, unlike a conventional molded surface fastener.
Consequently, an almost entire surface of the molded surface
fastener 1 engages the female engaging elements formed on the rear
surface of the surface skin material, an engaging strength is
improved remarkably. As a result, even if a force in a deflecting
direction is applied to a seating section of the surface skin
material, the surface skin material is not detached easily.
Further, a binding between the molded surface fastener 1 and the
surface skin material can follow up a slight motion between the
surface skin material and the cushion body, different from a
binding with a high strength yarn or thread and thus, the cushion
body is protected from a damage.
[0062] FIGS. 9 to 12 show a second embodiment of the present
invention. This second embodiment is different from the first
embodiment in structures of the division wall pieces 6 and the
engaging elements 3 disposed in a pair such that they are arranged
in the width direction. Because another structure is substantially
not different from the first embodiment, the same designations and
reference numerals as the first embodiment are used as designations
and reference numerals of components other than the different ones
in a following description.
[0063] According to this embodiment, instead of the division wall
pieces 6, a block piece 11 equal to the block piece 10 for joining
two pairs of engaging elements 3 disposed in the central portion in
the width direction of the molded surface fastener 1 of the first
embodiment is formed. As shown in FIGS. 9 and 11, two rows of the
division wall portions 5 on outermost and innermost sides of the
three longitudinal wall portions 4 located on extensions of the
engaging elements 3 extending in the width direction of the base
member 2 and the lateral wall portion 7 are joined together with a
first block piece 11 and further, three rows of the division wall
portions 5 are joined together with a second block piece 11. The
block piece 11 is buried in the cushion body so as to increase the
fixing strength of the molded surface fastener 1 due to the anchor
effect like the division wall pieces 6 of the first embodiment and
prevents the linear magnetic body 9 from being separated from the
base member 2.
[0064] According to the first embodiment, the engaging elements 3
disposed in a pair along the width direction of the base member 2
are provided independently. According to this embodiment, as shown
in FIGS. 9 and 10, the side surfaces of the rising portions of the
engaging elements 3 disposed in a pair along the width direction of
the base member 2 are combined and integrated with a reinforcement
rib 12. If the pair of engaging elements 3 arranged in the width
direction of the base member 2 are combined with each other with
the reinforcement rib 12 in this way, each engaging element 3 do
not fall down laterally when the surface skin material (not shown)
is pressed against the engaging-element forming surface of the
molded surface fastener 1 and its rising posture does not collapse.
As a result, the engaging elements 3 are more likely to be caught
by mating female engaging elements, thereby increasing the
engagement ratio to lead to an increase in an engagement force.
[0065] Other operation and effect are same as the first embodiment.
When the molded surface fastener 1 is integrated with the cushion
body at a time of formation by molding, the expandable resin
material is prevented from invading into the engaging-element
forming region of the molded surface fastener 1 surrounded by the
longitudinal wall portions 4 formed on the molded surface fastener
1 and the lateral wall portions 7 having a structure peculiar to
the present invention. Further, the engaging heads 8b of the
surface fastener formed integrally with the lateral wall portion 7
eliminate a generation of an engaging element missing section on a
substantial engagement surface of the molded surface fastener,
thereby improving a strength of engagement with the surface skin
material largely.
[0066] Typical embodiments of the present invention have been
described above. However, the present invention is not restricted
to the indicated examples and for example, it is permissible to
adopt various kinds of conventional well-known configurations for
the engaging elements, and it is permissible to form a recess in
the surface of the base member and erect the engaging elements from
a bottom surface of the recess so as to secure plasticity of the
molded surface fastener and consequently lower the heights of the
engaging elements, the longitudinal wall portions and the lateral
wall portion, thereby reducing a thickness of an entire molded
surface fastener.
* * * * *