U.S. patent application number 10/837346 was filed with the patent office on 2005-11-03 for refastenable garment attachment means with low impact on the garment.
Invention is credited to Efremova, Nadezhda, Kurtz, Wallace L. JR., Pierce, Joseph Earl, Tachauer, Ernesto S, VanBenschoten, Brian, Yu, Lisha.
Application Number | 20050241119 10/837346 |
Document ID | / |
Family ID | 34961530 |
Filed Date | 2005-11-03 |
United States Patent
Application |
20050241119 |
Kind Code |
A1 |
Efremova, Nadezhda ; et
al. |
November 3, 2005 |
Refastenable garment attachment means with low impact on the
garment
Abstract
A male component of a mechanical fastening system, such as a
hook and loop fastener, that can remain fastened to a female
component under high levels of shear force. The male component has
a backing material with protrusions extending from the backing
material at an angle toward the direction of fastener force. The
combination of the male component with a female loop component
results in a secure fastening system.
Inventors: |
Efremova, Nadezhda; (Neenah,
WI) ; Pierce, Joseph Earl; (Appleton, WI) ;
Yu, Lisha; (Appleton, WI) ; VanBenschoten, Brian;
(Newmarket, NH) ; Kurtz, Wallace L. JR.;
(Lunenburg, MA) ; Tachauer, Ernesto S; (Bedford,
NH) |
Correspondence
Address: |
KIMBERLY-CLARK WORLDWIDE, INC.
401 NORTH LAKE STREET
NEENAH
WI
54956
|
Family ID: |
34961530 |
Appl. No.: |
10/837346 |
Filed: |
April 30, 2004 |
Current U.S.
Class: |
24/442 |
Current CPC
Class: |
Y10T 24/27 20150115;
A44B 18/0015 20130101; A61F 13/5611 20130101; A61F 13/622
20130101 |
Class at
Publication: |
024/442 |
International
Class: |
A44B 018/00 |
Claims
We claim:
1. A mechanical fastening system comprising: a male component
including a backing material and a plurality of protrusions
extending from the backing material and having a height from about
3.times.10.sup.-3 cm to about 0.9 cm; and, a female component
capable of engaging the male component, wherein at least a portion
of the plurality of protrusions extend from the backing material of
the male component form an angle .alpha. from about 5 degrees to
about 85 degrees and at least a portion of the plurality of
protrusions have a Flexural Modulus from about 331 MPa to about
2,758 MPa.
2. The mechanical fastening system of claim 1, wherein the
mechanical fastening system has a peel force during disengagement
from about 0.2 N/m to about 50 N/m.
3. The mechanical fastening system of claim 1, wherein the
mechanical system exhibits a shear force during disengagement from
about 6.08.times.10.sup.3 N/m.sup.2 to about 2.43.times.10.sup.4
N/m.sup.2.
4. The mechanical fastening system of claim 1, wherein the female
component further comprises material selected from the group of
fabrics consisting essentially of: woven textile fabric; knitted
textile fabric; non-woven web; and, combinations thereof.
5. The mechanical fastening system of claim 1, wherein the female
component further comprises a loop backing material and a plurality
of loops or fibers extending from the loop backing material.
6. The mechanical fastening system of claim 1, wherein at least a
portion of the plurality of the protrusions extend from the backing
material of the male component at an angle substantially
perpendicular to the backing material of the male component.
7. The mechanical fastening system of claim 1, wherein at least a
portion of the plurality of protrusions extend from the backing
material of the male component at an angle .alpha. of about 15
degrees to about 85 degrees relative to the backing material of the
male component.
8. An absorbent article comprising the mechanical fastening system
of claim 1.
9. The absorbent article of claim 8, wherein the absorbent article
is selected from the group consisting essentially of: a diaper; a
training pant; a feminine hygiene product; an incontinence product;
a wound care product; and, medical garment.
10. A mechanical fastening system comprising: a male component
wherein the male component comprises a backing material and a
plurality of first protrusions and a plurality of second
protrusions extending from the backing material; and, a female
component capable of engaging the male component; wherein the
plurality of first protrusions extend from the backing material of
the male component at an angle .alpha. of about 5 degrees to about
85 degrees relative to the backing material of the male component
and the plurality of second protrusions extend from the backing
material of the male component at an angle .alpha. of about 95
degrees to about 175 degrees relative to the backing material of
the male component.
11. The mechanical fastening system of claim 10, wherein the female
component further comprises material selected from the group
consisting essentially of: textile fabric; knitted textile fabric;
non-woven web; and, combinations thereof.
12. The mechanical fastening system of claim 10, wherein the female
component further comprises a loop backing material consisting of a
plurality of loops or fibers extending from the loop backing
material.
13. The mechanical fastening system of claim 10, wherein at least a
portion of the plurality of the first protrusions are shorter than
at least a portion of the plurality of the second protrusions.
14. The mechanical fastening system of claim 13, wherein the
shorter first protrusions are from about 5% to 95% shorter than at
least a portion of the plurality of the second protrusions.
15. An absorbent article comprising the mechanical fastening system
of claim 10.
16. The absorbent article of claim 15, wherein the absorbent
article is selected from the group consisting essentially of: a
diaper; a training pant; a feminine hygiene product; an
incontinence product; a wound care product; and, medical
garment.
17. The mechanical fastening system of claim 10, wherein at least a
portion of the plurality of the first protrusions have a Flexural
Modulus from about 331 MPa to about 2,758 MPa.
18. The mechanical fastening system of claim 10, wherein at least a
portion of the plurality of the second protrusions have a Flexural
Modulus from about 331 MPa to about 2,758 MPa.
19. The mechanical fastening system of claim 10, wherein the
mechanical system has a peel force during disengagement from about
0.2 N/m to about 50 N/m.
20. The mechanical fastening system of claim 10, wherein the
mechanical system exhibits a shear force during disengagement from
about 6.08.times.10.sup.3 N/m.sup.2 to about 2.43.times.10.sup.4
N/m.sup.2.
Description
BACKGROUND OF THE INVENTION
[0001] The use of fastening systems on disposable absorbent
products, such as diapers, training pants, adult incontinent
products, feminine care products, and the like, is well known.
These fastening systems include pins, ties, buttons, snaps,
adhesives, and mechanical fastening systems. Key performance
requirements of such fastening systems include a balance of
maintaining the position of the absorbent products during use and
low/no impact on the garments that the fastening system comes into
contact with or utilizes during the use of the absorbent
product.
[0002] Refastenable mechanical fastening systems such as
Velcro.RTM.-style hook and loop mechanical fastening systems are
well known in the art. Typically, such fastening systems involve
two major components, a male component and a female component that
when engaged can hold two substrates together. The male component
typically includes a backing material with a number of protruding
hook elements that are designed to engage with a number of loops on
a complimentary female component. These hook elements protruding
from the backing material of the male component typically consist
of a base, a shank and an engaging means in the form of a hook, a
cap, a spherical/hemi-spherical shape, a flat top, etc. Generally,
a loop fastening material comprises fibrous loops protruding from
the backing material and is capable of engaging the above-described
male component of a mechanical fastener.
[0003] When the mechanical fastening system becomes engaged, a hook
element penetrates the loop fastening material and either engages
or intercepts fibrous loops of the loop fastening material. This
results in a mechanical interference and physical obstruction which
prevent the removal of hook material from the loop material until
the separation forces, usually in the form of either peel or shear
forces, exceed a certain threshold. After this, the disengagement
of a mechanical fastener occurs resulting in separation of the hook
component and the loop component. Furthermore, the separation
forces being applied to the loop material during the disengagement
stage can result in loop breakage, fiber pull-out and fiber
string-out, fuzzy marks on the loop material etc., up to mechanical
tear of the loop material.
[0004] The common way to avoid these problems is to use a female
component of a mechanical fastening system that is specifically
designed to engage with a particular male component and thus
possesses a necessary mechanical strength, fiber strength, fiber
thickness, and/or a particular fiber bonding pattern, in order to
prevent the above-mentioned problems. Examples of suitable loop
materials include Velcro.RTM. brand loop materials sold by Velcro
USA of Manchester, N.H., stitchbonded fabric sold by the Milliken
& Company of Spartanburg, S.C., or a loop material available
from Guilford Mills, Inc., Greensboro, N.C. under the trade
designation No. 36549. Another suitable loop material can comprise
a pattern un-bonded web as disclosed in U.S. Pat. No. 5,858,515
issued on Jan. 12, 1999 to Stokes et. al. The fact that the dual
surface (i.e., two separate surfaces) is required to enable hook
and loop style mechanical fastener makes it a costly material,
decreases flexibility of mechanical fastening system, and therefore
creates limitations for its use.
[0005] Mechanical fastening systems have been devised which provide
for repeated refastening as well as being lightweight and secure.
Hook and loop type mechanical fastening systems, such as
Velcro-style fasteners, are well known in the art. Such fastening
systems involve two major components, a male component and a female
component. The male component typically includes a backing material
with a number of protruding hooks that are designed to engage with
a number of loops on a complimentary female component. The hooks
protruding from the backing material of the male component
typically project perpendicularly to the direction of fastener
shear force. The hooks typically have a base, a shank, and an
engaging means in the form of a hook, cap, or spherical or
hemispherical shape. Generally, loop fastening materials will
comprise loops, fibers, or the like with the engaging elements of
the hook fastening material can become entangled.
[0006] When the mechanical fastening system is fastened and shear
force acts upon the fastening system, the hooks pull toward the
direction of fastener force. As the hooks are pulled which can
result in the hooks releasing the loops, the mechanical fastening
system may become unfastened as a final result. Furthermore, the
fastener force applied to the loops during disengagement may result
in damage to the loops, such as loop breakage, fiber pull-out and
string-out. Furthermore, the male component often produce
red-marking and irritation if brought into contact with a person's
skin, such as an infant's skin in contact with a male component of
a diaper mechanical fastening system.
[0007] There is a need or desire for a male component of a
mechanical fastening system that is capable of remaining fastened
to a female component under effective levels of shear force while
not damaging or distorting the female component.
[0008] There is a need or desire for a more universal male
component of a mechanical fastening system that is capable of
engaging into a wide variety of different potential female
components, such as fabrics used in garment manufacturing, e.g.
knitted fabrics, woven fabrics, non-woven fabrics, and the like.
There also is a need or desire for a male component of a mechanical
fastening system that is capable of remaining fastened to an
above-specified group of female components under in-use levels of
shear force while not damaging or distorting the female component.
There is also a need or desire for a male component that is capable
to release or disengage from the female component under the
effective levels of peel force during disengagement while not
damaging or distorting the female component. There is also a need
or desire for a male component that can be securely re-attached to
the female component after disengagement.
[0009] There is also a need or desire for a male component of a
mechanical fastening system that reduces or eliminates the
occurrence of red-marking and/or irritation if brought into contact
with a person's skin.
SUMMARY OF THE INVENTION
[0010] The present invention is directed to a male component of a
mechanical fastening system such as hook and loop fastener,
comprising protrusions wherein at least a portion of the
protrusions may be angled toward the direction of fastener shear
force acting on the mechanical fastening system in use. The angled
protrusions may withstand a higher shear force than conventional
perpendicular hooks on the male component without becoming
disengaged from the female component, such as loop material,
resulting in an advantageously more secure mechanical fastening
system. The angled protrusions of the male component may be
disengaged from the female component of the mechanical fastening
system without causing damage to the above-mentioned female
component. The angled protrusions on the male component may reduce
skin irritation often caused by perpendicular hooks.
[0011] The angled protrusions are non-hook type angled protrusions
located on the male component. In some embodiments of the present
invention, the entire surface of the male component may be covered
with angled protrusions, the surface of the male component may have
a combination of perpendicular protrusions and angled protrusions,
or the surface of the male component may have a combination of
zones covered with angled/perpendicular protrusions and zones with
no protrusions. The protrusions, angled and/or perpendicular, on
the male component may have similar or different heights.
[0012] The angled protrusions may be formed from a mold designed to
produce such protrusions, or from a mold specially shaped to
produce angled protrusions when the male component is removed from
the mold. In some situations, the protrusions may be formed from a
mold designed to produce perpendicular protrusions, and then angled
in the after-treatment. Alternatively, the angled protrusions may
be formed by using two or more polymers side-by-side in a mold,
such that the protrusions become angled as the polymers cool due to
differential shrinkage of the polymers.
[0013] With the foregoing in mind, it is a feature and advantage of
the present invention to provide a male component of a mechanical
fastening system that may remain fastened to a female component
under the in-use levels of shear force without causing noticeable
damage or distortion of the female component.
[0014] It is another feature and advantage of the present invention
to provide a male component of a mechanical fastening system that
may be released or disengaged from the female component under
effective levels of peel force without causing noticeable damage or
distortion of the female component.
[0015] It is another feature and advantage of the present invention
to provide a male component of a mechanical fastening system that
may engage a variety of different materials serving as female
components, such as knitted, non-woven, and woven materials.
[0016] It is yet another feature and advantage of the present
invention to produce a mechanical fastening system that includes
the above male component.
[0017] It is another feature and advantage of the present invention
to provide a male component of a mechanical fastening system that
reduces or eliminates the occurrence of red-marking and/or
irritation if brought into contact with a person's skin.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a side view of a male component and a female
component of a mechanical fastening system of the present invention
prior to engagement with one another;
[0019] FIG. 2 is a side view of a male component of a mechanical
fastening system of the present invention shown in partial
engagement with a female component;
[0020] FIG. 2a is a side view of a male component of a mechanical
fastening systems of the present invention shown in partial
disengagement from a female component by the application of a peel
force.
[0021] FIG. 3 is a perspective view of a male component of a
mechanical fastening system of the present invention;
[0022] FIG. 4 is a side view of an angled protrusion on a male
component of a mechanical fastening system of the present
invention;
[0023] FIG. 5 is a side view of an angled protrusion on a male
component of a mechanical fastening system of the present invention
engaged with a female component;
[0024] FIG. 6a-b is a side view of an angled protrusion on a male
component of a mechanical fastening system of the present
invention;
[0025] FIGS. 7a-7d are side views of angled protrusions on male
components of mechanical fastening systems of the present
invention;
[0026] FIGS. 8 a-8f are cross-sectional views of protrusions of
mechanical fastening systems of the present invention;
[0027] FIG. 9 is a plan view of a garment-facing side of a
disposable absorbent article incorporating a male component of a
mechanical fastening system of the present invention;
[0028] FIG. 10 is a side view of an angled protrusion comprised of
two different materials on a male component of a mechanical
fastening system of the present invention.
[0029] FIG. 11 is a plan view of a garment-facing side of an
absorbent article consisting of multiple groups of protrusions.
[0030] FIGS. 12a-12d are microphotographs of some loop materials at
a magnification
[0031] FIG. 13a is a microphotograph of loop material before the
engagement of a conventional hook material.
[0032] FIG. 13b is a microphotograph of loop material after the
engagement of a conventional hook material and subsequent
disengagement of the conventional hook material.
[0033] FIGS. 14a-14b are top plan views of portions of a male
component of mechanical fastener with angled protrusions.
[0034] FIGS. 14c-14d are side views of portions of a male component
of mechanical fastener with angled protrusions.
[0035] FIGS. 15a-15c are bar graphs showing of pore size
distributions of loop materials.
[0036] FIGS. 16a-16d are schematic drawings of void patterns of
loop materials.
DEFINITIONS
[0037] Within the context of this specification, each term or
phrase below will include the following meaning or meanings.
[0038] "Angled Protrusion" refers to a protrusion comprising a base
and a shank that extends from the backing of a male component of a
mechanical fastening system, and is non-perpendicular to a male
component backing.
[0039] "Comprises", "Comprising" and other derivatives from the
root term "comprise" are intended to be open-ended terms that
specify the presence of any stated features, elements, integers,
steps, or components, but do not preclude the presence or addition
of one or more other features, elements, integers, steps,
components, or groups thereof. Accordingly, such terms are intended
to be synonymous with the words "has", "have", "having",
"includes", "including" and any derivatives of these words.
[0040] "Direction of Fastener Force" refers to a force exerted by
the male component on the female component while the components are
engaged (e.g. while the article embodying the fastener is being
worn). The fastener force is a vector force having a shear force
component and a normal force component.
[0041] "Engaging Portion" refers to a part of a fastening component
that is suitably shaped to enable the fastening component to engage
or secure itself to a complementary fastening component. Examples
of engaging portions include J-shaped hooks, and flat-topped hook
portions atop protrusions having a diameter narrower than the flat
top.
[0042] "Extensible Material" refers to a material that can a
provide a substantially permanent deformation of at least about 10
percent, desirably at least about 15 percent, particularly at least
about 17 percent, more desirably at least about 20 percent, even
more desirably at least about 25 percent, and yet even more
desirably at least about 30 percent when subjected to a tensile
force of 100 gmf per inch (per 2.54 cm) of width according to the
Material Elongation and Deformation Tensile Test set forth herein.
In general, the Material Elongation and Deformation Tensile Test is
conducted similar to ASTM Standard Test Method D882 (Tensile Method
for Tensile Properties of Thin Plastic Sheeting) dated December
1995. The initial separation of the jaws of the tensile tester is 3
inches (76.2 mm) at a tensile force of about 1 gram force per inch
of width of the test sample, and the moving jaw is moved at a
constant rate of 127 mm/min. The moving jaw is stopped at an
extension where the tensile force equals 100 grams force per inch
of width of the test sample, held at that extension for a period of
2 minutes, and then returned back to its initial tensile force of
about 1 gram force per inch of width of the test sample at a rate
of 127 mm/min.
[0043] "Knitted Fabric" refers to a cloth constructed by
interlocking a series of loops of one or more yarns by hand or by
machine, by a knitting process. Three main classes of knit fabrics
are circular knit, flat knit and warp knit. Examples of the last
type of knit include Tricot, Milanese and Raschel knit.
[0044] "Knitting Process" refers to a method of constructing fabric
by interlocking series of loops of one or more yarns.
[0045] "Meltblown Fibers" means fibers formed by extruding a molten
thermoplastic material through a plurality of fine, usually
circular, die capillaries as molten threads or filaments into
converging high velocity heated gas (e.g., air) streams which
attenuate the filaments of molten thermoplastic material to reduce
their diameter, which may be to microfiber diameter. Thereafter,
the meltblown fibers are carried by the high velocity gas stream
and are deposited on a collecting surface to form a web of randomly
dispersed meltblown fibers. Such a process is disclosed for
example, in U.S. Pat. No. 3,849,241 to Butin et al. Meltblown
fibers are microfibers which may be continuous or discontinuous,
are generally smaller than 10 microns in diameter, and are
generally self bonding when deposited onto a collecting surface.
Meltblown fibers used in the present invention are preferably
substantially continuous in length.
[0046] As used herein, the term "Non-elastic", what is meant is
that the sheet layers are made from polymers that are generally
considered to be inelastic. In other words, use of such inelastic
polymers to form the sheet layers would result in sheet layers that
are not elastic. As used herein, the term "Elastic" means any
material which, upon application of a biasing force, is
stretchable, that is, elongatable, at least about 60 percent (i.e.,
to a stretched, biased length which is at least about 160 percent
of its relaxed unbiased length), and which will immediately recover
at least 55 percent of its elongation upon release of the
stretching, elongating force.
[0047] As used herein, the term "Non-woven" means a fabric or web
having a structure of individual fibers or threads which are
interlaid, but not in a regular or identifiable manner as in a
knitted textile or woven textile fabric. Non-woven fabrics or webs
have been formed from many processes such as, for example,
melt-blowing processes, spunbonding processes, air laying
processes, and bonded carded web processes. The basis weight of
non-woven fabrics is usually expressed in ounces of material per
square yard (osy) or grams per square meter (gsm) and the fiber
diameters useful are usually expressed in microns. (Note that to
convert from osy to gsm, multiply osy by 33.91.)
[0048] "Perpendicular Direction" or "Perpendicular Force Direction"
refers to a direction normal (90 degrees) to a backing material or
other reference surface. The perpendicular direction is
perpendicular to the shear direction, defined below.
[0049] "Perpendicular Force", or "peel force" refers to forces that
tend to produce an opposite pulling motion in a perpendicular
direction between two bodies' planes.
[0050] "Polymers" include, but are not limited to, homopolymers,
copolymers, such as for example, block, graft, random and
alternating copolymers, terpolymers, etc. and blends and
modifications thereof. Furthermore, unless otherwise specifically
limited, the term "polymer" shall include all possible geometrical
configurations of the material. These configurations include, but
are not limited to isotactic, syndiotactic and atactic
symmetries.
[0051] "Releasably Attached," "Releasably Engaged" and variations
thereof refer to two elements being connected or connectable such
that the elements tend to remain connected absent a separation
force applied to one or both of the elements, and the elements
being capable of separation without substantial permanent
deformation or rupture. The required separation force is typically
beyond that encountered while wearing the garment item.
[0052] "Resilient" refers to a material that is flexible,
compressible and re-formable.
[0053] "Shear Force" refers to forces that tend to produce an
opposite but parallel sliding motion between two bodies'
planes.
[0054] "Shear Direction" or "Shear Force Direction" refers to a
direction parallel to a backing material or other reference surface
undergoing shear force.
[0055] As used herein, the term "Spunbonded Fibers" refers to small
diameter fibers which are formed by extruding molten thermoplastic
material as filaments from a plurality of fine capillaries of a
spinnerette having a circular or other configuration, with the
diameter of the extruded filaments then being rapidly reduced as
by, for example, in U.S. Pat. No. 4,340,563 to Appel et al., and
U.S. Pat. No. 3,692,618 to Dorschner et al., U.S. Pat. No.
3,802,817 to Matsuki et al., U.S. Pats. No. 3,338,992 and 3,341,394
to Kinney, U.S. Pat. No. 3,502,763 to Hartmann, U.S. Pat. No.
3,502,538 to Petersen, and U.S. Pat. No. 3,542,615 to Dobo et al.,
each of which is incorporated herein in its entirety by reference.
Spunbond fibers are quenched and generally not tacky when they are
deposited onto a collecting surface. Spunbond fibers are generally
continuous and of-ten have average diameters larger than about 7
microns, more particularly, between about 10 and 30 microns.
[0056] "Thermoplastic" describes a material that softens when
exposed to heat and which substantially returns to a nonsoftened
condition when cooled to room temperature.
[0057] "Water-permeable Porous Films" refers to films rendered
porous by puncturing or aperturing, and to films rendered porous by
mixing polymer with filler, forming a film from the mixture, and
stretching the film.
[0058] "Woven Fabric" refers to fabric that is formed by a weaving
process of interlacing of at least two sets of yarns. Woven fabric
may be composed of two sets of yarns, warp and filling. Woven
fabrics may be composed of three sets of yarn to provide a triaxial
weave. Two dimensional woven fabrics may be composed of two or more
warps and fillings in a fabric, depending on the complexity of the
construction of the fabric. The manner in which the two sets of
yarn are interlaced determines the weave. The weaving process may
include one or more basic weaves, such as plain, twill, and
satin.
[0059] "Yarn" refers to a continuous strand of textile fibers,
filaments, or material in a form suitable for knitting, weaving, or
otherwise intertwining to form a textile fabric. Yarn may be
provided in the following forms: (1) a number of fibers twisted
together (spun yarn); (2) a number of filaments laid together
without twisting (a zero-twist yarn); (3) a number of filaments
laid together with a degree of twist; (4) a single filament with or
without twist (a monofilament); or, (5) a narrow strip of material,
including but not limited to, paper, plastic film, or metal foil,
or metal foil, with or without twist, intended for use in a textile
construction.
[0060] These terms may be defined with additional language in the
remaining portions of the specification.
DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS
[0061] The present invention is directed to a mechanical fastening
system that includes a male component and a female component. In
the present invention, a male component of a mechanical fastening
system, such as hook and loop fastener system, may be fastened to a
variety of different materials serving as a female component and
may remain securely fastened to the female component under
effective levels of shear force. The materials may include fabrics,
such as: (i) woven textile fabrics; (2) knitted textile fabrics;
and, (3) non-woven materials. For the purposes of the present
invention, the term "fabrics" is used to refer to woven, knitted,
and non-woven webs.
[0062] The present invention may also be directed to a male
component of a mechanical fastening system that may be easily
released or disengaged from the female component under the
effective levels of peel force without causing noticeable damage or
distortion to the loop material, and may be securely re-attached if
needed after several engagement disengagement cycles. The male
component includes protrusions wherein at least a portion of the
protrusions may extend from a backing material at an angle toward
the direction of fastener shear force. The geometry of the male
component can also reduce or eliminate the occurrence of
red-marking and/or irritation if brought into contact with a
person's skin during use of the disposable absorbent article.
[0063] The male component of mechanical fastening system of the
present invention may be utilized when a material comprising the
male component would be attached in a refastenable manner to a
garment or an undergarment material. Examples of applications of
this particular type of mechanical fastener include, but are not
limited to using a male component of the present invention to:
[0064] (1) refastenably attach a shoulder strap or another part of
an undergarment, e.g. brassiere, to the undersurface of an
overlying garment or used to attach any piece of one garment, e.g.
an undergarment such as panties or breast caps, to overlying
garments, thereby preventing shifting during use;
[0065] (2) secure a disposable absorbent article, such as an adult
incontinence pad or a feminine care pad, to the wearer's
undergarment;
[0066] (3) adjust the waistline of a garment or an undergarment by
either tightening or un-tightening waistline band or waistline
flaps, and re-attaching them to the garment and/or to themselves at
a desirable waistline width or used to close and/or adjust width of
collars, sleeve cuffs, or leg cuffs of garments;
[0067] (4) attach various functional and fashionable additions to a
garment article, e.g. additional pockets, re-attachable sleeves,
re-attachable hoods, or seasonal decorative appliqus, such as
pumpkin or autumn leaf shapes for Thanksgiving, or used to create a
wide variety of fashionable, decorative designs from the same basic
piece of garment;
[0068] (5) make creativity toys for kids, e.g. animal and alphabet
shapes that can be attached to a fabric covered board;
[0069] (6) refastenably attach name tags and visitors badges to the
garments;
[0070] It should be appreciated by those skilled in the art that
these examples are given for purposes of illustration and are not
to be construed as limiting the scope of the application of the
present invention.
[0071] This male component is particularly suitable for use in
mechanical fastening systems on disposable absorbent articles in
which the fastener force has a significant shear force component
during use. The term "disposable absorbent garments" is intended to
refer to any disposable garment intended to absorb discharged body
fluids. Examples of disposable absorbent garments include diapers,
adult incontinence products, training pants, feminine napkins,
wound dressings, and the like. For ease of understanding, much of
the following description will be made in terms of the use of the
mechanical fastening systems of the present invention on disposable
absorbent products, such as, feminine care products and disposable
diapers. Nonetheless, it is to be understood that the mechanical
fastening systems of the present invention are equally suited for
use on any other disposable absorbent products or durable
products.
[0072] As shown in FIG. 1, a male component 20 and a female
component 22 may be brought together to be releasably attached, or
releasably engaged, to one another. The male component 20 may have
a number of individual stems or protrusions 23 extending from a
resilient backing material 26. Similarly, the female component 22
may have a number of individual loops 28 protruding generally
perpendicularly from a resilient loop backing material 30. It is
understood, as used herein, the female component 22 may comprise a
part or a component of a garment article; alternatively, the female
component 22 may comprise a part or a component of the disposable
absorbent article 10 or a knitted textile fabric, woven textile
fabric, and/or non-woven web that the disposable absorbent article
10 comes in contact with during use. The individual protrusions 23
of the male component 20 and the loops 28, such as individual
fibers or bungles of fibers, of the female component 22, when
brought into contact with one another, engage or interlock with one
another, with the protrusions 23 of the male component 20 latching
onto the loops 28 of the female component 22, until forcibly
separated, thereby pulling the protrusions 23 of the male component
20 out of the loops 28 of the female component 22. The male and/or
female components 20 and 22, respectively, may be attached to the
disposable absorbent article 10 or to a peripheral portion thereof,
such as wing structures.
[0073] In some embodiments of the present invention, the individual
loops 28 of the female component 22 may be needled, stitched or
otherwise projected through the loop backing material 30. The loop
backing material 30, or alternatively, the female component 22 may
suitably be made from a non-woven material. In another embodiment
of the present invention, the female component 22 may suitably be
made from a fibrous non-woven web such as a spunbond non-woven web,
or a staple fiber carded web. An example of a suitable non-woven
web is disclosed in U.S. Pat. No. 5,858,515 to Stokes, et. al, and
is hereby incorporated by reference. Alternatively, the individual
loops 28 may be made of yarn or tow. Once the loops 28 have been
formed, fibers forming the loops 28 may be anchored in place by
bonding the fibers to the loop backing material 30 with heat and/or
adhesives or any other suitable means. Such suitable female
components 22 are available from Velcro, USA, of Manchester, N.H.
Alternatively, the female component 22 may be a woven or knitted
textile fabric, such as one of the fabrics conventionally used for
garment or underwear manufacturing. It is to be understood that the
individual loops 28 may not protrude from the surface of the female
component 22 but may be an integral part of a fabric, as in typical
knitted textile fabric, woven textile fabric, or non-woven
webs.
[0074] At least some of the individual angled protrusions 24 of the
male component 20 of the present invention may be angled, at least
in part, toward the direction of fastener shear force. As used
herein, the term "direction of fastener shear force" refers to a
shear component of a direction, i.e., the direction of fastener
force, which a male component 20 applies to a mating female
component 22 when the male and female components 20 and 22,
respectively, are engaged and under tension. FIG. 2 shows the male
component 20 and the female component 22 of FIG. 1 in an engaged
position under tension, wherein part of the male and female
components 20 and 22 are undergoing disengagement. The direction of
fastener force is indicated by arrow 32 in FIGS. 1 and 2. The
direction of fastener shear force is indicated by arrow 31 in FIGS.
1 and 2. The direction of a perpendicular peel force component of
the fastener force is indicated by arrow 33 in FIGS. 1 and 2. As
shown in FIGS. 1 and 2, as typically observed during use, the shear
component of the force acting on the mechanical fastening system
may be much higher than the peel component of the force acting on
the mechanical fastening system. The fastener shear force is in
direct opposition to shear force exerted by the female component 22
against the male component 20. If the angled protrusions 24 of the
male components 20 are relatively flexible, the loops 28 of the
female component 22 may bend the angled protrusions 24 in a
direction opposite the direction of their original tilt, as shown
in FIG. 2. Alternatively, the angled protrusions 24 may be
relatively stiff, thereby latching the loop 28 between the
protrusion 24 and the backing material 26, as shown in FIG. 5, and
providing for a very secure attachment.
[0075] When it is necessary to disengage or unfasten a mechanical
fastening system, an unfastening force having a higher
perpendicular peel force component than parallel shear force
component may be applied to the mechanical fastening system (see
FIG. 2a). The geometry of the angled protrusions 24 and properties
of the materials making up the angled protrusions 24 may ensure
that the loop 28 are not pulled out from or otherwise damaged
during the release stage. The angled protrusions 24 may require
only slight deformation, such as bending, to be released, which can
be achieved by application of the low-to-moderate levels of
perpendicular peel force. Thus, much lower values of forces may be
applied to the female component 22 during the separation stage in
case of angled protrusions 24 than in case of a conventional hook
material-based male component. In order to further reduce or
prevent damage to the female component 22 during the release stage,
only the materials with the appropriate flexibility characteristics
may be chosen for manufacturing of angled protrusions 24, i.e.
materials with Flexural Modulus of between about 331 MPa to about
2,758 MPa (see more detailed discussion of the flexibility of
protrusions below), alternatively, about 344.7 MPa to about 2,413
MPa, or alternatively about 413.7 MPa to about 2,344 MPa. The lower
limit of the Flexural Modulus may be independently about 331 MPa,
about 344.7 MPa, about 379.2 MPa, or about 413.7 MPa. The upper
limit of the Flexural Modulus may be independently about 2,344 MPa,
about 2,413 MPa, or about 2,758 MPa.
[0076] For some embodiments of the present invention, the materials
may have a Flexural Modulus of between about 331 MPa to about 586.
MPa, alternatively, about 338 MPa to about 572 MPa, or
alternatively, about 345 MPa to about 552 MPa. The lower limits of
the Flexural Modulus may be independently about 331 MPa, about 338
MPa, or about 345 MPa. The upper limit of the Flexural Modulus may
be independently about 552 MPa, about 572 MPa, or about 586
MPa.
[0077] In some embodiments of the present invention, the materials
may have a Flexural Modulus of between about 965 MPa to about 1,379
MPa, alternatively, about 1,034 MPa to about 1,310 MPa, or
alternatively, about 1,103 MPa to about 1,241 MPa. The lower limits
of the Flexural Modulus may be independently about 965 MPa, about
1,034 MPa, or about 1,103 MPa. The upper limit of the Flexural
Modulus may be independently about 1,241 MPa, about 1,310 MPa, or
about 1,379 MPa.
[0078] In other embodiments of the present invention, the materials
may have a Flexural Modulus of between about 1,724 MPa to about
2,344 MPa, alternatively, about 1,793 MPa to about 2,275 MPa, or
alternatively, about 1,862 MPa to about 2,206 MPa. The lower limits
of the Flexural Modulus may be independently about 1,724 MPa, about
1,793 MPa, or about 1,862 MPa. The upper limit of the Flexural
Modulus may be independently about 2,206 MPa, about 2,275 MPa, or
about 2,344 MPa.
[0079] The angled projections 24 may be able to handle a greater
amount of fastener shear force 31 exerted by the female component
22 than typical perpendicular projections 25 because the female
component 22 must overcome a greater amount of fastener shear force
31 when the angled projections 24 are angled toward the direction
of fastener shear force 31. Male components 20 having angled
projections 24 thereby may result in a more secure fastening
system. To address opposite directions of fastener shear force 31
that may be subjected to the mechanical fastening system during use
and separation, depending on the directions in which the female
component 22 moves during use and during separation from the male
component 20, angled projections 24 are suitably located in
opposite directions, as illustrated in FIG. 3. Furthermore, the
angled projections 24 and perpendicular projections 25 reduce the
number of sharp ends poking a wearer by pointing sharp ends away
from the wearer, and may thus reduce skin irritation often caused
by conventional hook structures.
[0080] All of the individual protrusions 23 of the male component
20 may be angled protrusions 24 which are angled toward the
direction of fastener shear force 32 or, alternatively, some of the
individual protrusions 23 may be angled protrusions 24, angled
toward the direction of fastener force 32 and some of the
individual protrusions 23 may be perpendicular protrusions 25,
roughly perpendicular to the backing material 26 (and roughly
perpendicular to the direction of fastener shear force 31). A
combination of angled protrusions 24 and perpendicular protrusions
25 is shown in FIG. 1 and FIGS. 9 and 11. Individual angled
protrusions 24 that are angled non-perpendicular to the backing
material 26 are suitably at an angle (a) of about 5 degrees to
about 85 degrees with respect to the backing material 26 (and the
direction of fastener shear force 31), more suitably at an angle
(a) of about 15 degrees to about 80 degrees, more suitably at an
angle (a) of about 15 degrees to about 75 degrees, more suitably at
an angle (a) of about 20 degrees to about 75 degrees, more suitably
at an angle (a) of about 30 degrees to about 75 degrees, most
suitably at an angle (a) of about 35 degrees to about 70 degrees
(See FIGS. 7a-7d). The lower limit of the angle (a) of the
individual protrusions 23 may be independently about 5 degrees,
about 15 degrees, about 20 degrees, about 30 degrees, or about 35
degrees. The upper limit of the angle (a) of the individual
protrusions 23 may be independently about 85 degrees, about 80
degrees, about 75 degrees, or about 70 degrees.
[0081] Individual protrusions 25 that are roughly perpendicular to
the backing material 26 and direction of fastener shear force 31,
are suitably at an angle (a) of about 70 degrees to about 110
degrees with respect to the backing material 26, more suitably at
an angle (a) of about 80 degrees to about 100 degrees, and most
suitably at an angle (a) of about 85 degrees to about 95 degrees.
The lower limit of the angle (a) of the individual protrusions 25
may be independently about 70 degrees, about 80 degrees, or about
85 degrees. The upper limit of the angle (a) of the individual
protrusions 25 may be independently about 110 degrees, about 100
degrees, or about 95 degrees.
[0082] The protrusions 23 of the male component 20 penetrate the
surface of or otherwise interact with the female component 22. The
protrusions 23 of the male component 20 may comprise a variety of
sizes and shapes. FIGS. 7a to 7d show four side views of different
shapes that the protrusions 23 may assume. The protrusions 23 may
terminate in tapered ends (see FIG. 7b) or may comprise conical or
pyramidal shapes (see FIG. 7c). In other embodiments, the
protrusions 23 may comprise the shape of a truncated cone or a
truncated pyramid (see FIG. 7d). FIGS. 8a to 8f show six additional
cross-sectional views of shapes that the protrusions 23 may also
assume.
[0083] It may be desirable that the cross-sectional dimensions of
the protrusions 23 of the male components 20 of the present
invention are comparable or smaller than the size of the void
spaces between the fibers in the female component 22. The
cross-sectional dimensions of the protrusions 23 may range from
about 90 to about 500 .mu.m, more specifically from about 130 to
about 440 .mu.m, and most specifically from about 160 to about 400
.mu.m. The lower limit of the cross-sectional dimension of the
protrusions 23 may be independently about 90 .mu.m, about 130
.mu.m, or about 160 .mu.m. The upper limit of the cross-sectional
dimension of the protrusions 23 may be independently about 500
.mu.m, about 440 .mu.m, or about 400 .mu.m. The cross-sectional
dimensions of the protrusions 23 may be variable along the length
of protrusion as shown in FIGS. 6b, and 7b to 7d. Such variability
in the cross-sectional dimensions of the protrusions 23 may allow
the protrusions 23 to penetrate and engage a variety of female
components 22 having void spaces of different sizes or variable
sizes. In an alternative embodiment, male component 20 may include
two or more groups of protrusions 23, each group of protrusions 23
being characterized by specific cross-sectional dimensions (see
FIGS. 9 and 11), thereby enabling the male component 20 to attach
to a variety of female components 22.
[0084] The angled projections 24 may be more angled along a small
portion, such as at one end 27, as shown in FIG. 6, or along a
substantial length of the angled projection 24, as shown in FIGS. 4
and 5. The term "substantial length," as used herein, refers to the
full length of the angled projection 24.
[0085] In accordance with some embodiments, the male components 20
of the present invention may generally have between about 16 and
about 930 protrusions 23 per square centimeter, more specifically
between about 124 and about 470 protrusions 23 per square
centimeter, and most specifically between about 155 and about 310
protrusions 23 per square centimeter. In other embodiments of the
present invention, the male components 20 may generally have
between about 250 to about 800 protrusions 23 per square
centimeter, more specifically between about 350 to about 700
protrusions 23 per square centimeter, and most specifically between
about 400 to about 600 protrusions 23 per square centimeter. In
other embodiments of the present invention, the protrusions 23 of
the male components 20 may form a discontinuous pattern, such as
stripes and isolated islands, wherein the number of protrusions 23
may range from about 5 protrusions 23 per square centimeter or
greater.
[0086] The heights h of the protrusions 23 of the male components
20 of the present invention may range from about 3.times.10.sup.-3
cm to about 0.9 cm, more specifically from about
2.4.times.10.sup.-2 cm to about 5.5.times.10.sup.-2 cm, and most
specifically from about 2.8.times.10.sup.-2 cm to about
5.times.10.sup.-2 cm. The lower limit of the height of the
protrusions 23 may be independently about 3.times.10.sup.-3 cm,
about 2.4.times.1 0.sup.-2 cm, or about 2.8.times.10.sup.-2 cm. The
upper limit of the height of the protrusions 23 may be
independently about 0.9 cm, about 5.5.times.10.sup.-2 cm, or about
5.times.10.sup.-2 cm. (See FIGS. 7a to 7d). The height of the
protrusions 23 should provide effective engagement of the
protrusions 23 of the male component 20 and the female component
22.
[0087] The protrusions 23 may be formed by injection molding,
cavity molding, profile extrusion, or any other fabricating process
known in the art. For example, the protrusions 23 may be suitably
molded or extruded using a continuous molding process, in which a
plastic resin strip base is molded with integral fastener elements
in the form of protrusions extending from one surface. Such molding
may be performed in a high pressure nip, such as between two
counter-rotating rollers or against a single roller that defines
miniature cavities in its peripheral surface, the cavities may be
shaped in such a way that the cavities would be suited for molding
any shape of the protrusions 23, including the shapes shown in
FIGS. 6 and 7a-d. One process is described in the U.S. Pat. No.
4,794,028, issued on Dec. 27, 1988 to Fisher, and incorporated
herein by reference to the extent it is consistent herewith.
Alternatively, a method of in situ lamination of protrusions 23 to
the backing material 26 may be used, as disclosed in U.S. Pat. No.
5,260,015, issued on Nov. 9, 1993 to Kennedy et. al., and
incorporated herein by reference to the extent it is consistent
herewith. The materials for making the protrusions 23 may be
selected from a group of thermoplastic polymers such as polyamides,
polyesters, poly(vinyl acetate), PVC, polyolefins (e.g.
polyethylene, polypropylene, polybutene, ethylene copolymers,
propylene copolymers, or butene copolymers), a thermoplastic
elastomer, or another suitable material and mixtures thereof.
[0088] The Flexural Modulus of the material from which the
protrusions 23 may be suitably molded or extruded should be in the
range from about 331 MPa to about 2,758 MPa. As used herein, the
term "Flexural Modulus" is used as an equivalent of a term "Modulus
of Elasticity in Bending" and refers to a characteristic of the
flexural properties of plastics determined according to ASTM D
790-99 "Standard Test Methods for Flexural Properties of
Unreinforced and Reinforced Plastics and Electrical Insulating
Materials". Protrusions 23 having such flexural modulus provides
for acceptable engagement with the female component 22 while
maintaining flexibility to allow disengagement from the female
component 22 without causing significant damage. Other parameters
of the protrusions 23 that may affect the flexibility, engagement
and disengagement characteristics of the protrusions 23 include,
but are not limited to: (a) the length/height of a protrusion 23;
(b) the angle .alpha. between the protrusion 23 and the backing
material 26; and, (c) the cross-sectional area (or shape) of the
protrusions 23. As the cross-sectional area of protrusions 23 is
increased (e.g., thicker stems), the flexibility of the protrusions
23 may decrease. To compensate for reduced flexibility of the
protrusions 23, selection of materials having lower Flexural
Modulus may be made. Likewise, when the angle .alpha. between the
protrusions 23 and the backing material 26 is decreased, or when
the length of protrusions 23 is increased, the selection of
materials having an appropriate Flexural Modulus may be needed to
provide protrusions 23 of desired flexibility. For example,
materials having a lower Flexural Modulus to increase the
flexibility of the protrusions 23, thereby and thus avoid
significant separation forces acting on the female component 22
during disengagement.
[0089] The protrusions 23 may be comprised of more than one
material. In some embodiments of the present invention, the
protrusions 23 may be made of one polymer or material that may
provide a desired trait or characteristic and be coated with
another polymer or material that may provide an additional trait or
characteristic. For example, the protrusion 23 may be comprised of
polypropylene which may provide a mechanical strength. Such a
protrusion 23 may then be coated with a pliable or elastomeric
material, such as a silicone rubber, ethyl-vinyl-acetate (EVA),
homo- and co-polymers of isoprene, homo- and co-polymers of
butadiene, and the like, to provide a softer, more skin-friendly
surface and a surface with a higher coefficient of friction, such
as materials with a coefficient of friction higher than 1.
[0090] Alternatively, the method of manufacture may be modified by
using at least two different polymers 38 and 40 aligned
side-by-side along a length of the protrusion mold. When the
polymers 38 and 40 are heated, all of the polymers 38 and 40 should
be heat softened. In some embodiments of the present invention, the
polymers 38 and 40 may be chosen such that one polymer 38 shrinks
more than the other polymer 40 or other polymers during the cooling
process. Thus, when the polymers 38 and 40 cool, the polymer 38
that shrinks more lowers the protrusion 24 toward the backing
material 26 while the polymer 40 that shrinks less forms a surface
away from the backing material 26, as shown in FIG. 10.
[0091] The backing material 26 may be made of any of the materials
that comprise the protrusions 23 or any other suitable materials.
The backing material 26 may be made of the same or a different
material than the protrusions 23 of the male component 20. The
backing material 26 may generally have a thickness in a range of
between about 0.1 millimeter (mm) and about 5 mm, suitably in a
range of between about 0.6 mm and 2 mm, resulting in a total basis
weight of the male component 20 in a range of from about 20 grams
per square meter to about 200 grams per square meter. In various
embodiments of the present invention, the backing material 26 may
comprise a film, a paper, a knit fabric, woven, needle punched
non-woven, spunbond, point-unbonded non-woven material (PUB), neck
bonded laminate (NBL), spunbond/meltblown/spunbond multi-layer
laminate, air laid non-woven, air-formed non-woven, and the
like.
[0092] The protrusions 23 of the male component 20 of the present
invention may be spatially arranged in rows with spacers 29 between
the rows, as shown in FIG. 3. These spacers 29 may be in the form
of bumps, ridges, depressions, or any other suitable distortion
made in or added to the backing material 26. These spacers 29 may
improve the overall flexibility of the backing material 26 by
providing areas of lower density among the individual protrusions
23 where the backing material 26 may easily bend to conform to a
wearer's body as the body moves. Furthermore, the spacers 29 may
also improve the flexibility of individual protrusions 23 by
providing room for the individual protrusions 23 to bend in
response to applied pressure. Alternatively, the rows of
protrusions 23 may be separated by a flat surface. Also, as
mentioned, the protrusions 23 may be suitably arranged such that a
plurality of the protrusions 23 face one direction and a plurality
of the protrusions 23 may face an opposite direction or a different
direction in order to compensate for directions of fastener forces
in opposite/different directions. See FIGS. 9 to 10 and FIGS. 14a
to 14b for examples of possible orientations of angled protrusions.
In other embodiments of the present invention, the angled
protrusions 24 of the male component 20 may be randomly oriented in
different directions. The orientations may be in the machine
direction (MD) and/or cross-machine direction (CD) and any
orientation therebetween.
EXAMPLES
Example 1
[0093] It may be desirable that the spatial parameters of the
protrusions 23 of the male component 20 of the present invention,
such as their cross-sectional dimensions, length, height and
surface density be designed taking in the account properties of the
targeted female component 22 or a group of targeted female
components 22.
[0094] The samples of materials taken from feminine undergarments
analyzed were:
[0095] 1. Samples of black knitted nylon material, commercially
available under the trade designation of "non-cling Tricot 40
denier Antron III sanitized", purchased from Kieffer's Company,
located at P.O. Box 719, Jersey City, N.J., 07307.
[0096] 2. Samples of 100% black cotton jersey, commercially
available under the style/color number 0808-6175 and weight of 6.85
ounce per sq. yard, purchased from Dyersburg Fabric Inc., located
at Dyersburg, Tenn., 38024.
[0097] 3. Samples of beige satin material taken from various
regions of the high-cut Satin ladies briefs sold under Vanity
Fair.RTM. of the Vanity Fair Corporation located at 105 Corporate
Center Blvd., Greensboro, N.C., 27408. Briefs were purchased
through the J.C. Penney Company.
[0098] 4. Samples of blue microfiber material taken from various
regions of the high-cut microfiber ladies briefs sold under Vanity
Fair.RTM. of the Vanity Fair Corporation located at 105 Corporate
Center Blvd., Greensboro, N.C., 27408. Briefs were purchased
through the J.C. Penney Company.
[0099] The samples of the materials represent typical types of
materials used in feminine undergarments. The samples of the
materials represent different types of fibers (synthetic and
natural) and different types of weaves (less dense, such as the
cotton jersey sample of material and more dense, such as the satin
sample of material).
[0100] The following undergarment material parameters were obtained
as discussed below:
[0101] 1. Average pore sizes
[0102] 2. Pore size distribution
[0103] 3. Pore density
[0104] 4. Weave pattern
[0105] 5. Average material thickness
[0106] These parameters were used to establish suitable dimensions
for protrusions 23 of a male component 20 capable of engaging
materials typically used in feminine undergarments.
[0107] Determination of the pore dimensions, pore density, and
weave pattern were made by analysis of micro-images of undergarment
samples of the materials. The micro-images were obtained using the
high-resolution Keyence.RTM. Digital Microscope VH-6300
commercially available from Keyence Corporation located at 1-3-14,
Higashi-Nakajima, Higashi-Yodogawa-ku, Osaka, 533, Japan. The
micro-images were obtained using a magnification of 50.times. for
the pore density determination, and a magnification of 175.times.
for the pore size determination. All measurements were taken while
the samples of material were experiencing no stress or elongation
forces.
[0108] The pore size determination of each sample of material was
accomplished using the "Measure" option on the controller unit of
the microscope. Before each measurement, a calibration of distance
was performed for measurement accuracy. To measure the size of a
pore, a Keyence.RTM. VH-6300 Camera unit (complimentary to the
Keyence.RTM. Digital Microscope) was focused on the sample of
material being analyzed so that the image of the sample was
displayed clearly on the monitor screen. A pore region was then
secluded by a polygon shape outlining the shape of the pore region
being measured. Measurement of the polygon area was performed by
using "Area" option on the controller menu of the microscope. The
measurement was repeated at least 50 times. At least three pieces
of each sample of material were used for measurement, from
different regions of the sample of material. An average value of
the measurements was calculated. For simplification of the
calculations, different polygon shapes representing different pore
shapes were approximated by circles of equal area, and the circle
diameter was used as a parameter characterizing pore size of any
particular pore. FREQUENCY function in Excel.RTM. software (a part
of the standard Microsoft Office Software Package) was used to
analyze pore sizes distribution.
[0109] The determinations of pore density and weave pattern of each
sample of material was accomplished using micro-images of 50.times.
magnification. The micro-images were made using the high-resolution
Keyence.RTM. Digital Microscope VH-6300. The "X-Y distance" option
on a controller menu was used to determine the distances between
the adjacent pores in X and Y directions of each sample of
material. The measurement was repeated at least 15 times. At least
three pieces of each sample of material were used for measurement,
from up to 5 different regions of the sample of material. An
average value of the measurements was calculated. Standard
deviations were calculated using Excel.RTM..
[0110] The thickness of each sample of material was measured using
digital thickness tester from SONY at 1.38 kPa. The measurement was
repeated at least 15 times. At least three pieces of each sample of
material were used for measurement, from up to 5 different regions
of the sample of material. An average value of the measurements was
calculated.
[0111] FIGS. 15a-15c show the pore size distributions for the
different types of materials, cotton, nylon, microfiber and satin.
The cotton, nylon, and microfiber materials were all showing broad
bi-modal distributions of pore sizes, reflecting the fact that
these materials, with a complex weave pattern, had two types of
pores, large and small (as shown in FIGS. 16a-16d). The satin
material showed a more uniform unimodal pore size distribution
consistent with its more uniform weave pattern (see FIG. 12 and
FIG. 16d). The average pore sizes for all four materials are
summarized in Table 1.
[0112] Differences in weave patterns of different materials are
more easily observed in the microphotographs of the materials
presented in FIGS. 12a-12d. FIG. 12a is a microphotograph of the
nylon sample of material. FIG. 12b is a microphotograph of the
cotton sample of material. FIG. 12c is a microphotograph of the
microfiber sample of material. FIG. 12d is a microphotograph of the
satin sample of material. The weave patterns of the four samples of
material were different. The weave pattern of the cotton sample of
material was the least dense and the weave pattern of the satin
sample of material was the most dense. The cotton sample of
material also exhibited a higher degree of `fuzziness` due to
single fibers projecting from the yarns. Schematic drawings of void
patterns for the four samples of the materials are shown in FIGS.
16a-16d. To quantify densities of the weave patterns of the four
samples of materials, the number of pores per square inch was
determined for each sample. The determination was accomplished by
measuring average distances between the adjacent pores in both the
MD and CD directions. The average pore densities are provided in
Table 1. Densities of the samples of materials as determined are:
Cotton<Microfiber.ltoreq.Nylon<Satin. The cotton sample of
material was about 2.5 times less dense than the microfiber sample
of material, while the satin sample of material was about 2.7 times
more dense than the nylon sample of material.
[0113] The results of the thickness determination of the samples of
the materials are also provided in Table 1.
1 TABLE 1 Nylon Cotton Microfiber Satin Pore Sizes Ave. Dia., .mu.m
150 380 158 196 Min. Dia., .mu.m 93 280 107 151 Max. Dia., .mu.m
228 462 226 239 Stnd dev., .mu.m 31 48 38 21 AVE. Distance Between
Pores: in CD, .mu.m 545 1,022 407 240 Stnd dev., .mu.m 20 37 1 2 in
MD, .mu.m 485 702 706 392 Stnd dev., .mu.m 33 15 3 5 Pore Surface
Density Ave. density, voids/cm.sup.2 757 279 696 2,129 Stnd dev.,
voids/cm.sup.2 52 6 3 24 Ave. density, voids/inch.sup.2 4,882 1,800
4,490 13,136 Stnd dev., voids/inch.sup.2 332 38 19 144 Thickness
Ave. thickness, .mu.m 280 680 300 300 Stnd dev., .mu.m 20 20 30
30
[0114] Suitable designs and dimensions of the male component 20
capable of engaging with various female components 22 having
different pore sizes, pore densities, weave patterns, and
thicknesses are described below. Suitable cross-sectional
dimensions of protrusions 23 and 25 of the male component 20 may
have comparable cross-sectional dimensions of material voids within
the female component 22. If the cross-sectional dimensions of the
protrusions 23 and/or 25 of the male component 20 differ
significantly from the cross-sectional dimensions of the material
voids within the female component 22 (greater or less than), the
engagement may fail. If the cross-sectional dimension of the
protrusions 23 and/or 25 of the male component is significantly
greater than the material voids within the female component 22, the
protrusions 23 and/or 25 may not be able to penetrate the female
component 22. If the cross-sectional dimension of the protrusions
23 and/or 25 of the male component 20 is significantly less than
the material voids within the female component 22, the engagement
of the male component 20 and female component 22 may not be able to
be maintained during use. The cross-sectional dimensions of
protrusions 23 and/or 25 of the male component 20 may be within the
range between about 90 .mu.m to about 470 .mu.m, alternatively
about 100 .mu.m to about 460 .mu.m, or alternatively about 110
.mu.m to about 450 .mu.m. The lower limit of the cross-sectional
dimension of the protrusions 23 and/or 25 of the male component 20
may be independently about 90 .mu.m, about 100 .mu.m, about 110
.mu.m, or about 120 .mu.m. The upper limit of the cross-sectional
dimension of the protrusions 23 and/or 25 of the male component 20
may be independently about 440 .mu.m, about 450 .mu.m, about 460
.mu.m, or about 470 .mu.m.
[0115] The protrusions 23 and/or 25 of the male component 20 may
include a variety of cross-sectional shapes, such as cones,
pyramids, tapered cones, tapered pyramids, truncated cones, and the
like. Wherein the protrusions 23 and/25 have a tapered shape, such
protrusions 23 and/or 25 may more easily penetrate or otherwise
engage a wider variety of different female components 22
characterized by different pore sizes and other characteristics
affecting penetration and engagement by protrusions 23 and/or 25.
This may be explained by the varying cross-sectional dimension
through the length of the protrusion 23 and/or 25.
[0116] In other embodiments of the present invention, the male
component 20 may include more than one type of protrusions 23
and/or 25. Each type of protrusions 23 and/or 25 may have
cross-sectional dimensions and/or cross-sectional shapes that may
be corresponding to a particular range of material voids within a
female component 22. As such, the male component 20 may demonstrate
improved engagement with a variety of different female components
22. In some embodiments of the present invention, similar
protrusions 23 and/or 25 may be positioned within islands, stripes,
or other configurations on the surface of the male component
20.
[0117] In some embodiments of the present invention, the height of
protrusions 23 and/or 25 of the male component 20, as measured from
the base to the tip of the protrusions 23 and/or 25 may be less
than the thickness of female component 22. Such a configuration of
the protrusions 23 and/or 25 may avoid direct skin contact, and
thus, skin irritation, with the protrusions 23 and/or 25 of the
male component 20. In some embodiments of the present invention,
the heights of the protrusions 23 and/or 25 of the male component
20 may be about 250 .mu.m to about 700 .mu.m, alternatively about
280 .mu.m to about 680 .mu.m, or alternatively about 300 .mu.m to
about 670 .mu.m. The lower limit of the height of the protrusions
23 and/or 25 of the male component 20 may be independently about
200 .mu.m, about 250 .mu.m, about 275 .mu.m, or about 300 .mu.m.
The upper limit of the cross-sectional dimension of the protrusions
23 and/or 25 of the male component 20 may be independently about
700 .mu.m, about 690 .mu.m, about 680 .mu.m, or about 670
.mu.m.
[0118] The surface density, the number of protrusions 23 and/or 25
per square centimeter of the male component 20, may range from
about 270 prot./cm.sup.2 to about 2,200 prot./cm.sup.2,
alternatively about 290 prot./cm.sup.2 to about 2,000
prot./cm.sup.2, alternatively about 300 prot./cm.sup.2 to about
1,800 prot./cm.sup.2, or alternatively about 320 prot./cm.sup.2 to
about 1,600 prot./cm.sup.2. The lower limit of the surface density
of the male component 20 may be independently about 250
prot./cm.sup.2, about 270 prot./cm.sup.2, about 290 prot./cm.sup.2,
about 300 prot./cm.sup.2, or about 320 prot./cm.sup.2. The upper
limit of the surface density of the male component 20 may be
independently about 2,200 prot./cm.sup.2, about 2,000
prot./cm.sup.2, about 1,800 prot./cm.sup.2, or about 1,600
prot./cm.sup.2.
Example 2
[0119] To illustrate the correlation between the separation forces
acting on a mechanical fastener during disengagement and the level
of damage to the female component, a testing of the forces
experienced by the mechanical fastening system during the
disengagement in peel and shear mode was conducted. Tests were
conducted using a standard tensile frame Model Number Sintech I/S,
serial No. 7190, equipped with TestWorks for Windows software from
MTS Systems Corporation located at P.O. Box 24012, Minneapolis,
Minn., 55424, in accordance with the manufacturer's manual. The 50
N transducer was used together with the tensile frame to measure
forces, and the instrument was calibrated for this transducer
before each test. The loop material was in the form of knitted
nylon material, commercially available under the trade designation
"non-cling Tricot 40 denier Antron III sanitized", manufacturer
part number 4500 T "Antron" III, purchased from Kieffer's Co.
located at P.O. Box 719, Jersey City, N.J., 07307. The material was
cut in 2".times.8" (51 mm.times.203 mm) samples for the peel test.
For the purpose of repeatability of the force measurements, male
component was always engaged to the loop material by rolling the
sample with a mechanical roll-down unit providing a pressure of 2
kg twice at a speed of 4.9 mm/s. The material was peeled from the
male component of a mechanical fastener at a 180-degree angle and
at a peel speed of 20 inches/minute (8.47 mm/s) and the resulting
peel force was recorded. In a separate series of tests, the
material was separated from the male component in sheer mode at a
speed of 20 inch/minute (8.47 mm/s) and the resulting sheer force
was recorded.
2TABLE 2 Average peel forces measured during disengagement of the
male component 20 from the female component 23 by peel forces and
resulting levels of loop damage. Average force during disengagement
by peel, Level of damage to the No. Code name N/m loop material 1
100-7003 2.3 No 2 102-7004 3.9 No 3 102-7003 4.6 No 4 100-7005 5.2
No 5 102-1002 7.4 No 6 61-1036 7.7 No 7 102-7006 9.4 no 8 100-1001
12.3 no 9 61-1035 12.7 no 10 102-7005 19.0 no 11 103-7005 22.8
slight 12 103-1001 24.7 slight 13 102-1001 47.8 moderate 14 38-1002
235.4 severe
[0120]
3 Protrusion Flexural Protrusion Density Modulus Code Shape Angle
.alpha. (prot./cm.sup.2) (MPa) 38-1002 see FIG. 6b 37.degree. 182
61-1035 see FIG. 6a 90.degree. 455 2,034 .+-. 310 61-1036 see FIG.
6a 90.degree. 455 100-1001 see FIG. 6b 60.degree. 672 2,034 .+-.
310 100-7003 see FIG. 6b 60.degree. 672 448 .+-. 138 100-7005 see
FIG. 6b 60.degree. 672 1,172 .+-. 207 102-1001 see FIG. 6b
60.degree. 336 2,034 .+-. 310 102-1002 see FIG. 6b 75.degree. 336
2,034 .+-. 310 102-7003 see FIG. 6b 60.degree. 336 448 .+-. 138
102-7004 see FIG. 6b 75.degree. 336 448 .+-. 138 102-7005 see FIG.
6b 60.degree. 336 1,172 .+-. 207 102-7006 see FIG. 6b 75.degree.
336 1,172 .+-. 207 103-1001 see FIG. 6a 60.degree. 336 2,034 .+-.
310 103-7005 see FIG. 6a 60.degree. 336 1,172 .+-. 207
[0121] As shown in Table 2, the loop material 30 did not experience
any damage if the average peel force during disengagement was lower
than about 22.8 N/m. It was further demonstrated that when the
average peel force was above about 22.8 N/m but below about 47.8
N/m only a slight impact on the loop material 30 was observed
resulting in a slight increase of fuzziness of the surface of the
loop material 30. However when the average peel force during
disengagement was about 47.8 N/m or higher, a moderate amount of
damage to the loop material 30 was observed resulting in a
noticeable string-out and fiber pull-out, and a significant
increase of fuzziness of the surface of the loop material 30, so
that the area where a male component 20 was attached became clearly
noticeable and different in appearance from the rest of the female
component 22. It was further demonstrated that when the average
peel force reached the level of about 235.4 N/m or higher, a severe
damage to the female component 22 was observed. The level of damage
was comparable to the damage caused to the loop material 30 by the
conventional hook material as demonstrated in FIGS. 13a-13b.
[0122] It is to be understood that the present invention is aimed
at the male component 20 of the mechanical fastener that can only
cause no impact or slight impact on the female component 22. Thus,
the male component 20 of the present invention may exert a peel
force on a nylon female component 22 that ranges from about 0.2 N/m
to about 47.8 N/m, alternatively about 0.4 N/m to about 47.5 N/m,
alternatively about 0.8 N/m to about 47.1 N/m, or alternatively
about 2.3 N/m to about 46.3 N/m. The lower limit of the peel force
may be independently about 0.2 N/m, about 0.4 N/m, about 0.8 N/m,
or about 2.3 N/m. The upper limit of the peel force may be
independently 46.3 N/m, about 47.1 N/m, about 47.8 N/m.
[0123] Table 3 provides data of the shear forces measured during
the separation of the male component 20 from the female component
22 in the shear mode. The female component 22 was the sample of
material of nylon. No significant damage, as discussed above, was
recorded during the separation of the male component 20 from the
female component 22 under the application of peel force. In some
embodiments of the present invention, the shear force during the
separation of the male component 20 from the female component 22 in
the shear mode may be in the range from about 6.08.times.10.sup.3
N/m.sup.2 to about 2.43.times.10.sup.4 N/m.sup.2, alternatively
about 6.38.times.10.sup.3 N/m.sup.2 to about 2.42.times.10.sup.4
N/m.sup.2, alternatively about 6.68.times.10.sup.3 N/m.sup.2 to
about 2.40.times.10.sup.4 N/m.sup.2, or alternatively about
7.00.times.10.sup.3 N/m.sup.2 to about 2.34.times.10.sup.4
N/m.sup.2. The lower limit of the peel force may be independently
about 6.08.times.10.sup.3 N/m.sup.2, about 6.38.times.10.sup.3
N/m.sup.2, about 6.68.times.10.sup.3 N/m.sup.2, or about
7.00.times.10.sup.3 N/m.sup.2. The upper limit of the peel force
may be independently about 2.43.times.10.sup.4 N/m.sup.2, about
2.42.times.10.sup.4 N/m.sup.2, about 2.40.times.10.sup.4 N/m.sup.2,
or about 2.34.times.10.sup.4 N/m.sup.2.
4TABLE 3 Average Shear Forces Measured during Disengagement of the
Male Component 20 from the Female Component 23 Shear Mode. Average
force during disengagement by shear, No. Code name N/m.sup.2 1
100-7003 6.38 .times. 10.sup.3 2 102-7004 4.56 .times. 10.sup.3 3
102-7003 6.99 .times. 10.sup.3 4 100-7005 2.28 .times. 10.sup.4 5
102-1002 1.28 .times. 10.sup.4 6 61-1036 7.29 .times. 10.sup.3 7
102-7006 1.73 .times. 10.sup.4 8 100-1001 1.73 .times. 10.sup.4 9
61-1035 1.99 .times. 10.sup.4 10 102-7005 2.37 .times. 10.sup.4 11
103-7005 2.64 .times. 10.sup.4 12 103-1001 2.34 .times.
10.sup.4
[0124] It will be appreciated that details of the foregoing
embodiments, given for purposes of illustration, are not to be
construed as limiting the scope of this invention. Although only a
few exemplary embodiments of this invention have been described in
detail above, those skilled in the art will readily appreciate that
many modifications are possible in the exemplary embodiments
without materially departing from the novel teachings and
advantages of this invention. Accordingly, all such modifications
are intended to be included within the scope of this invention,
which is defined in the following claims and all equivalents
thereto. Further, it is recognized that many embodiments may be
conceived that do not achieve all of the advantages of some
embodiments, particularly of the preferred embodiments, yet the
absence of a particular advantage shall not be construed to
necessarily mean that such an embodiment is outside the scope of
the present invention.
* * * * *