U.S. patent application number 15/665520 was filed with the patent office on 2017-11-16 for longitudinal bead molding.
The applicant listed for this patent is Velcro BVBA. Invention is credited to Earl Lorne Cowley, Victor Horst Kheil, Paul Joseph Voigt.
Application Number | 20170326775 15/665520 |
Document ID | / |
Family ID | 51660470 |
Filed Date | 2017-11-16 |
United States Patent
Application |
20170326775 |
Kind Code |
A1 |
Kheil; Victor Horst ; et
al. |
November 16, 2017 |
LONGITUDINAL BEAD MOLDING
Abstract
An edge-beaded fastener product such as a cushion cover tie-down
has a molded profile bead secured to and extending along a flexible
strip adjacent a longitudinal edge of the strip. The profile bead
has a shoulder or an inboard sidewall extending away from the
strip, such as for retaining a clip or hog ring. The flexible strip
may have a reinforced region, inboard of the shoulder, in which
resin contiguous with resin forming the profile bead encapsulates
surface features of the strip. The product is made by molding resin
directly onto the strip. Multiple lanes of resin may be molded on a
single substrate, which is severed to form individual strips with
severed, exposed strip edges.
Inventors: |
Kheil; Victor Horst;
(Kitchener, CA) ; Cowley; Earl Lorne; (Ajax,
CA) ; Voigt; Paul Joseph; (Waterdown, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Velcro BVBA |
Deinze |
|
BE |
|
|
Family ID: |
51660470 |
Appl. No.: |
15/665520 |
Filed: |
August 1, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
14493765 |
Sep 23, 2014 |
9776353 |
|
|
15665520 |
|
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|
61885692 |
Oct 2, 2013 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B29C 2793/0045 20130101;
Y10T 24/38 20150115; B29K 2101/12 20130101; B29C 2793/0036
20130101; B29L 2007/008 20130101; B29C 48/0022 20190201; B68G 7/12
20130101; B29C 43/28 20130101; B29K 2705/00 20130101; B29K 2105/256
20130101; B29C 48/05 20190201; B29C 43/222 20130101; B29C 48/15
20190201; B29C 48/21 20190201; B29C 2793/009 20130101; B29C 48/35
20190201 |
International
Class: |
B29C 47/06 20060101
B29C047/06; B29C 43/28 20060101 B29C043/28; B29C 47/00 20060101
B29C047/00; B29C 47/02 20060101 B29C047/02; B68G 7/12 20060101
B68G007/12; B29C 43/22 20060101 B29C043/22; B29C 47/32 20060101
B29C047/32 |
Claims
1-18. (canceled)
19. An edge-beaded fastener product comprising: an elongated,
flexible strip having opposite longitudinal edges; and a molded
profiled bead secured to and extending along the flexible strip
adjacent one of the longitudinal edges of the strip, the profiled
bead having an inboard sidewall extending away from the strip,
wherein the flexible strip has a reinforced region, inboard of the
inboard sidewall of the profiled bead, in which resin contiguous
with resin forming the profiled bead encapsulates surface features
of the strip, the reinforced region being of finite width and
having an inboard edge spaced from the profiled bead and the
longitudinal edges of the strip.
20. The fastener product of claim 19, further comprising a
longitudinal rib of resin at an inboard edge of the reinforced
region, the rib, reinforced region and profiled bead comprising
portions of a contiguous mass of resin.
21. The fastener product of claim 19, wherein the molded profile
bead is disposed adjacent an exposed longitudinal edge of the
strip.
22. The fastener product of claim 21, wherein the molded profile
bead has a severed edge coincident with the exposed longitudinal
edge of the strip.
23. The fastener product of claim 19, wherein the reinforced region
is at least as wide as the profile bead.
24. The fastener product of claim 19, wherein the profile bead is
longitudinally continuous.
25. The fastener product of claim 19, wherein the profile bead is
segmented, with segments of the profile bead spaced apart along an
edge of the strip.
26. The fastener product of claim 19, further comprising a pad of
resin projecting from a side of the strip within the reinforced
region, spaced from the longitudinal edges of the strip and aligned
with a gap between adjacent profile bead segments.
27. The fastener product of claim 19, further comprising a
longitudinal rib of resin at an inboard edge of the reinforced
region; wherein the rib, reinforced region and profile bead
comprise respective portions of a contiguous mass of resin.
28. The fastener product of claim 19, wherein the flexible strip
defines apertures through the strip.
29. The fastener product of claim 28, wherein the apertures are
disposed within the reinforced region.
30. The fastener product of claim 29, wherein the reinforced region
comprises rims of resin extending about the apertures and
projecting from the strip.
31. The fastener product of claim 19, wherein the profile bead is
disposed on only one broad side of the strip.
32. The fastener product of claim 19, wherein the profile bead
includes two bead portions each disposed on a respective side of
the strip and each having an inboard sidewall extending away from
the strip.
33. The fastener product of claim 19, wherein the profile bead has
a longitudinal flange extending away from the strip and disposed
inboard of the sidewall, such that the flange and sidewall define a
longitudinal recess therebetween.
34. The fastener product of claim 19, further comprising a wire
embedded within the profile bead.
35. A cushion cover tie-down comprising: an elongated, fabric strip
with opposite longitudinal edges; and a molded profile bead of
resin secured to and extending along the strip adjacent one of the
longitudinal edges; the profile bead comprising an inboard sidewall
extending away from the strip and disposed adjacent an exposed
longitudinal edge of the strip.
36. The cushion cover tie-down of claim 35, wherein the exposed
longitudinal edge of the strip features severed ends of fibers of
the fabric strip, with the bead of resin encapsulating surface
fibers of the strip adjacent the severed fiber ends.
37. The cushion cover tie-down of claim 35, wherein the molded
profile bead is contiguous with resin impregnating material of the
flexible strip in a reinforced region between the sidewall of the
molded profile bead and an exposed surface of the flexible
strip.
38. A cushion cover tie-down comprising: an elongated, fabric strip
with opposite longitudinal edges; and a molded profile bead of
resin secured to and extending along the strip adjacent one of the
longitudinal edges; wherein the profile bead comprises an inboard
sidewall extending away from the strip, and a longitudinal flange
extending away from the strip and positioned inboard of the
sidewall, such that the flange and sidewall define a longitudinal
recess therebetween.
Description
TECHNICAL FIELD
[0001] This invention relates to molding beads along fabric webs,
and particularly to forming fabric strips with edge listing beads
for use as tie-downs in retaining cushion covers and the like.
BACKGROUND
[0002] Fabrics carrying longitudinal ribs or beads of resin have
several uses. In one use, fabric strips having such a bead along
one edge are employed as tie-downs to secure upholstery or other
covers over seat cushions. In such applications the bead of resin
is commonly referred to as a listing bead, and it is known to
extrude such resin beads along a free edge of a strip of fabric,
such as in a one-up, two stage profile extrusion and overmolding
process to form such products. Tie-downs with listing beads can be
sewn into seams or to the edge of the upholstery and engaged with
clips or hog rings to hold the upholstery in place, either to a
foam cushion or directly to a seat frame.
[0003] Bead-carrying fabrics also have other uses. Improvements in
the methods of producing such products, and in the products
themselves, are sought, either for covering foam cushions or other
applications.
SUMMARY
[0004] One aspect of the invention features a method of making a
continuous sheet-form product carrying a profiled bead of resin
along a length thereof. The method includes continuously passing a
flexible substrate through a nip defined between two
counter-rotating rolls, introducing a flow of moldable resin into
the nip between the flexible substrate and a first of the two
rolls, in an area in which an outer surface of the first of the two
rolls defines a peripheral molding recess, and molding the resin in
the peripheral molding recess to form a profile bead bonded to a
side of the flexible substrate and extending along the substrate
between exposed regions of substrate surface. The recess is shaped
such that the profile bead defines a longitudinal slitting channel
extending along the flexible substrate, along which channel the
profile bead has a lesser tear resistance than on either side of
the channel.
[0005] In some cases, the method also includes slitting the profile
bead and substrate longitudinally along the slitting channel,
thereby forming two separate substrate strips each having a
corresponding portion of the bead extending along an exposed,
severed edge of the substrate.
[0006] The resin may be introduced in separate flows to two or more
spaced apart regions of the flexible substrate and molded in two or
more corresponding molding recesses of the first of the two rolls,
thereby forming two or more spaced-apart profile beads each
defining a slitting channel and each extending along the flexible
substrate between longitudinal exposed regions of substrate
surface. In some applications the method also includes slitting the
profile beads along the slitting channels, thereby forming three or
more separate substrate strips each having a corresponding profile
bead portion extending along a longitudinal edge thereof.
[0007] In some embodiments, a portion of the flowable resin engages
the outer surface of the first of the two rolls adjacent the
molding recess, and impregnates the substrate in a region
immediately adjacent the profile bead as the resin is molded,
thereby forming a reinforced region of the substrate adjacent the
profile bead.
[0008] In some cases, the method includes forming a series of
apertures extending through the reinforced region and spaced along
the substrate. Before forming the series of apertures, a series of
elevated pads may be molded, spaced along the substrate and through
which the apertures are formed, such that the formed apertures are
bounded by elevated rims of resin from the pads.
[0009] In some applications, the resin portion engaging the outer
surface of the first of the two rolls adjacent the molding recess
forms a layer of resin disposed on the substrate, thinner than the
profile bead, and disposed between the profile bead and an exposed
region of the substrate surface.
[0010] The outer surface of the first of the two rolls, in some
examples of the method, also defines a circumferential groove
extending about the first of the two rolls and spaced from the
peripheral recess. In such cases a rib of resin may be formed in
the groove, the rib forming a lateral edge of the reinforced
region.
[0011] In some examples, the substrate, as introduced to the nip,
defines holes that go through the substrate. The substrate is
introduced to the nip with the holes aligned with the moldable
resin, such that pressure in the nip forces some of the resin into
the holes. In some cases, a second of the two rolls has a surface
that defines a recess positioned to receive resin pressed through
the holes of the substrate in the nip, thereby forming a molded
protrusion of the resin on a side of the substrate opposite the
profile bead. The molded protrusion may be a longitudinally
continuous bead, for example.
[0012] In some embodiments the molded profile bead has a
longitudinal shoulder spaced laterally from the slitting
channel.
[0013] The substrate, in some applications, has a fabric surface on
which the profile bead is molded. The fabric surface may be of a
woven structure, for example. In some other examples, the fabric
surface may be of a knit or non-woven structure.
[0014] In some embodiments the method also includes passing the
substrate and profile bead through a second nip in which the formed
bead is plastically deformed to alter a shape of the profile bead.
In some cases the formed profile bead has flanges extending away
from the substrate on either side of the slitting channel, and
passing the substrate and profile bead through the second nip bends
the flanges toward the substrate.
[0015] In many cases the profile bead is longitudinally continuous
and of constant cross-section along the continuous length of the
substrate. In some other cases, the profile bead is of a
cross-section that varies along the substrate. For example, for
some applications the bead is segmented, with segments of the bead
being longitudinally spaced and each defining a shoulder
segment.
[0016] The peripheral recess may be, in some examples,
circumferentially discontinuous and include separate recess
cavities. Molding the resin may involve filling the separate
cavities from a continuous flow of the moldable resin.
[0017] In some embodiments, molding the resin further includes
molding a series of resin protrusions extending from the substrate
and spaced laterally from, and longitudinally between, adjacent
segments of the bead.
[0018] In some configurations, molding the resin includes pressing
resin through the substrate in spaces between the recess cavities,
thereby forming a longitudinally spaced series of protrusions on a
side of the substrate opposite the bead segments. The series of
protrusions may include, or be in the form of, bead segments each
defining a shoulder.
[0019] In some examples, the method includes introducing a
pre-formed, longitudinally continuous wire to the nip with the
moldable resin, such that the wire becomes embedded in the profile
bead as the resin is molded. The wire may comprise metal, for
example.
[0020] Another aspect of the invention features a method of making
a continuous flexible strip of substrate carrying a bead of resin
along an edge thereof. The method includes continuously passing a
flexible substrate sheet through a nip defined between two
counter-rotating rolls; introducing a flow of moldable resin into
the nip between the flexible substrate and a first of the two
rolls, in an area in which an outer surface of the first of the two
rolls defines a peripheral molding recess; and molding the resin in
the peripheral molding recess to form a profile bead bonded to a
side of the flexible substrate and extending along the substrate
between exposed regions of substrate surface The profile bead is
formed to have a cross-section that increases in thickness across a
tapered region of the profile bead to a longitudinal shoulder
defining an abrupt transition in bead thickness. The method also
includes longitudinally severing the substrate adjacent the tapered
region of the profile bead along a line spaced from the shoulder,
thereby forming a strip of the substrate carrying a bead of molded
resin adjacent a severed longitudinal edge of the strip.
[0021] In some embodiments the resin is introduced in separate
flows to two spaced apart regions of the flexible substrate and
molded in two corresponding molding recesses of the first of the
two rolls, thereby forming two spaced-apart profile beads each
extending along the flexible substrate between longitudinal exposed
regions of substrate surface.
[0022] In some cases, longitudinally severing the substrate
involves severing the substrate along parallel lines each adjacent
the tapered region of a respective one of the beads, thereby
forming multiple substrate strips each carrying a bead of resin
adjacent a severed edge of the strip.
[0023] In some examples of the method, a portion of the flowable
resin engages the outer surface of the first of the two rolls
adjacent the molding recess, and impregnates the substrate in a
region immediately adjacent the profile bead as the resin is
molded, thereby forming a reinforced region of the substrate
adjacent the profile bead. In some examples, the reinforced region
of the substrate and the tapered region of the profile bead are on
opposite sides of the longitudinal shoulder.
[0024] In some embodiments, the method also includes forming a
series of apertures extending through the reinforced region and
spaced along the substrate. In some examples a series of elevated
pads is molded along the substrate, and then the apertures are
formed through the pads, such that the formed apertures are bounded
by elevated rims.
[0025] In some embodiments, the outer surface of the first of the
two rolls further defines a circumferential groove extending about
the first of the two rolls and spaced from the peripheral recess,
and molding the resin forms a rib of resin in the groove, the rib
forming a lateral edge of the reinforced region.
[0026] As previously noted, the substrate, as introduced to the
nip, may have holes aligned with the moldable resin, such that
pressure in the nip forces some of the resin into the holes.
[0027] Other features discussed above may also be included in
various embodiments of this aspect of the invention, depending on
the circumstances.
[0028] According to another aspect of the invention, an edge-beaded
fastener product includes an elongated, flexible strip having
opposite longitudinal edges, and a molded profile bead secured to
and extending along the flexible strip adjacent one of the
longitudinal edges of the strip. The profile bead has an inboard
sidewall extending away from the strip, and the flexible strip has
a reinforced region, inboard of the inboard sidewall of the profile
bead, in which resin contiguous with resin forming the profile bead
encapsulates surface features of the strip. The reinforced region
is of finite width and has an inboard edge spaced from the profile
bead and the longitudinal edges of the strip.
[0029] In some embodiments, the molded profile bead is disposed
adjacent an exposed longitudinal edge of the strip. In some cases,
the molded profile bead has a severed edge coincident with the
exposed longitudinal edge of the strip.
[0030] In some examples, the reinforced region is at least as wide
as the profile bead.
[0031] In some configurations, the profile bead is longitudinally
continuous.
[0032] In some configurations the profile bead is segmented, with
segments of the profile bead spaced apart along an edge of the
strip.
[0033] Some examples also have a pad of resin projecting from a
side of the strip within the reinforced region, spaced from the
longitudinal edges of the strip and aligned with a gap between
adjacent profile bead segments.
[0034] Some examples have a longitudinal rib of resin at an inboard
edge of the reinforced region, with the rib, reinforced region and
profile bead all comprising portions of a contiguous mass of
resin.
[0035] In some cases the flexible strip defines apertures through
the strip. For some applications, the apertures are disposed within
the reinforced region. The reinforced region may include rims of
resin extending about the apertures and projecting from the
strip.
[0036] In some embodiments the profile bead is disposed on only one
broad side of the strip. In some other embodiments, the profile
bead includes two bead portions each disposed on a respective side
of the strip and each having an inboard sidewall extending away
from the strip.
[0037] In some configurations the profile bead has a longitudinal
flange extending away from the strip and disposed inboard of the
sidewall, such that the flange and sidewall define a longitudinal
recess therebetween. The longitudinal flange and sidewall may be of
a longitudinally discrete clip receiver portion of the profile
bead, for example.
[0038] The product may also include a wire embedded within the
profile bead and extending along the product.
[0039] Another aspect of the invention features a cushion cover
tie-down having an elongated, fabric strip with opposite
longitudinal edges, and a molded profile bead of resin secured to
and extending along the strip adjacent one of the longitudinal
edges. The profile bead has an inboard sidewall extending away from
the strip, and is disposed adjacent an exposed longitudinal edge of
the strip.
[0040] In some embodiments, the exposed longitudinal edge of the
strip features severed ends of fibers of the fabric strip, with the
bead of resin encapsulating surface fibers of the strip adjacent
the severed fiber ends.
[0041] In some examples the molded profile bead has a severed edge
coincident with the exposed edge of the fabric strip.
[0042] The molded profile bead may have an inboard edge spaced from
the exposed edge of the flexible strip, at which inboard edge the
sidewall is positioned.
[0043] In some embodiments, the molded profile bead is contiguous
with resin impregnating material of the flexible strip in a
reinforced region between the sidewall of the molded profile bead
and an exposed surface of the flexible strip. Some examples also
feature a longitudinal rib of resin projecting from the strip along
an inboard edge of the reinforced region. There may be a series of
discrete holes through the tie-down and at least partially defined
within the reinforced region.
[0044] As noted above, the profile bead may be disposed on only one
broad side of the strip, or may include two bead portions each
disposed on a respective side of the strip. Each may have an
inboard sidewall extending away from the strip, with the exposed
longitudinal edge exposed between the two bead portions.
[0045] Various features and characteristics of the profile bead
noted above with respect to a method aspect of the invention may be
found in various product embodiments.
[0046] Another aspect of the invention features a cushion cover
tie-down having an elongated, fabric strip with opposite
longitudinal edges, and a molded profile bead of resin secured to
and extending along the strip adjacent one of the longitudinal
edges, in which the profile bead has an inboard sidewall extending
away from the strip, and a longitudinal flange extending away from
the strip and positioned inboard of the sidewall, such that the
flange and sidewall define a longitudinal recess between them.
[0047] In some cases, the sidewall and flange are longitudinally
discontinuous and comprise segments spaced along the strip. The
segments may be connected by a longitudinally continuous rail of
resin.
[0048] In some examples the rail extends along the edge of the
strip.
[0049] The strip may have a reinforced region, inboard of the
flange of the profile bead, in which resin contiguous with resin
forming the profile bead encapsulates surface features of the
strip. The reinforced region is of finite width and has an inboard
edge spaced from the flange and the longitudinal edges of the
strip.
[0050] Another aspect of the invention features a cushion cover
with two or more flexible cover sections joined along a seam, and
one of the above-described cushion cover tie-downs joined to the
cover sections at the seam, with the profile bead spaced from the
cover sections.
[0051] The methods described herein can be employed to efficiently
produce continuous lengths of tie-downs or other beaded strips that
can be slit to width and/or cut to length for particular
applications. Such methods may be more cost-effective than
traditional edge over-molding extrusion techniques. Products
produced according to the concepts discussed herein can be
configured to fasten cushion covers, such as with manual or
automated manipulation and engagement of clips and latch elements
provided on the edge of a tie-down, or can be configured for other
useful purposes, such as providing a reinforcement or fastening
function at the edge of a flexible strip or sheet.
[0052] The details of one or more embodiments of the invention are
set forth in the accompanying drawings and the description below.
Other features, objects, and advantages of the invention will be
apparent from the description and drawings, and from the
claims.
DESCRIPTION OF DRAWINGS
[0053] FIG. 1 is a perspective view of a portion of a cushion
cover, showing a seam construction.
[0054] FIG. 2 is a partial cross-section view of a covered foam
cushion, showing the seam of the cover secured at a foam trench by
a hog ring.
[0055] FIG. 2A is a partial cutaway view of the covered foam
cushion trench of FIG. 2.
[0056] FIG. 3 is a partial cross-section view of a covered foam
cushion, showing the seam of the cover secured at a foam trench by
a plastic retainer clip.
[0057] FIG. 4 is an end view of a profile listing bead secured by a
plastic retainer clip.
[0058] FIGS. 5A and 5B show different listing bead profiles.
[0059] FIG. 5C shows a double listing bead profile formed at a
folded strip edge.
[0060] FIG. 6 schematically illustrates a method and apparatus for
producing a continuous sheet of fabric with laminated longitudinal
beads, such as for forming cushion cover tie-down strips.
[0061] FIG. 6A is an enlarged view into a portion of the forming
nip of the apparatus of FIG. 6, looking in the direction of resin
flow, showing resin being molded in a molding channel.
[0062] FIG. 7 illustrates a perspective view of a sheet of flexible
material formed on the apparatus of FIG. 6.
[0063] FIG. 8 shows resin contiguous with a profiled lane on one
side of the sheet extending through holes to the opposite side of
the sheet.
[0064] FIG. 9 shows a sheet of material to be slit adjacent molded
profile beads.
[0065] FIG. 10 illustrates a molded profile bead containing a
reinforcing wire, formed with an edge rib and an aperture rim.
[0066] FIG. 10A is a partial cross-sectional view, taken along line
10A-10A in FIG. 10.
[0067] FIG. 10B is a partial cross-sectional view of an alternate
construction.
[0068] FIG. 11 illustrates a sectioned profile bead, alternating
with molded inboard resin pads.
[0069] FIG. 12 shows a segmented profile bead, with alternating
segments on either side of a substrate edge.
[0070] FIG. 13 schematically illustrates a first method and
apparatus for producing a continuous sheet of fabric with
longitudinal beads of resin laminated on both sides.
[0071] FIG. 14 schematically illustrates a second method and
apparatus for producing a continuous sheet of fabric with
longitudinal beads of resin laminated on both sides.
[0072] FIG. 15 illustrates a perspective view of a sheet of
flexible material produced with the method of either FIG. 13 or
FIG. 14.
[0073] FIG. 16 shows a lightweight curtain, such as for separating
hospital room patient areas.
[0074] FIG. 17 shows three fabric strips sewn into a fabric as
stays.
[0075] FIG. 18 is an edge view of a flexible cover engaging an edge
of a rigid panel.
[0076] FIG. 19 shows a portion of a molding nip for forming a
preform from which the edge bead of the cover FIG. 18 is made.
[0077] FIG. 20 shows a preform formed in the nip of FIG. 19.
[0078] FIG. 21 shows the preform of FIG. 20 after deformation.
[0079] FIG. 22 shows a tie-down having a listing bead configuration
with spaced-apart clip receivers.
[0080] FIG. 23 is a cross-sectional view, showing the tie-down of
FIG. 22 secured in a clip in a cushion trench.
[0081] FIG. 24 shows permanently securing a clip receiver to the
edge of a substrate.
[0082] FIG. 25 shows the secured clip receiver of FIG. 24 engaged
by a clip.
[0083] Like symbols in different drawings indicate like
elements.
DETAILED DESCRIPTION
[0084] Referring first to FIG. 1, cushion cover 100 includes two
flexible fabric, resin or leather sections 101 and 103 joined along
a seam 105 by stitching 107. Also secured to the sections of the
cover by stitching 107 is a fabric strip 104 that carries, along
its free, distal, longitudinal edge a listing bead 102 protruding
from one side of the strip. The listing bead is formed of resin
molded onto a fabric web that forms the body of the strip. Strip
104 also features a reinforced region 108 extending upward from
bead 102, in which resin contiguous with resin forming the bead
reinforces the strip. The remainder of the strip, above region 108,
is free of reinforcing resin and retains its flexibility. In this
example, the strip also defines a series of apertures 110 extending
through the strip within reinforced region 108, just above listing
bead 102. Some examples are free of such apertures, and in some
other examples the apertures are disposed partially within, and
partially above the reinforced region of the strip, or fully above
the reinforced region. The apertures may be, for example, five to
six millimeters in diameter, and be spaced one to two millimeters
inboard of the listing bead.
[0085] The fabric of strip 104 may be, for example, a woven,
non-woven or knit fabric, such as are commonly employed in cushion
cover trim flags commonly referred to as tie-downs. Strip 104 may
be a textile sheet made of non-woven olefin fibers, such as
polyethylene or polypropylene. As an example, strip 104 may be
formed of material known commercially as DUON, manufactured by
Phillips Fiber Corporation. However, other sheet materials may be
used as desired, such as natural woven or non-woven textiles,
synthetic woven or non-woven textiles, or sewable thermoplastic
films.
[0086] Strip 104 is preferably sewn into the seam as the two cover
sections are joined, such that the strip depends from the edges of
the joined sections on an inner side of the cover at the seam.
[0087] As will be discussed further below, bead 102 is disposed
adjacent an exposed longitudinal edge of the fabric of strip 104,
and not formed to extend about, and envelop, the fabric edge as in
some earlier listing bead designs.
[0088] Referring next to FIGS. 2 and 2A, a foam cushion 200, such
as of an automotive seat, has a foam bun 202 covered with the
cushion cover of FIG. 1. The contoured outer bun surface features
an elongated trench 206 positioned beneath seam 105 and into which
strip 104 extends. The strip is held in place in the trench in this
example by metal hog rings 204 that each extend through a
respective one of the apertures 110 and around a wire 214 embedded
in the foam bun below the trench and running along the trench. The
strip 104 is held under tension by the hog rings, thereby holding
the cover tight against the surface of the foam bun 202. The
listing bead 102 bears at least some of the load applied by the hog
rings to strip 104, helping to prevent tearing of the strip
web.
[0089] Trench 206 is defined between two opposing side walls 208
and 210, and above a trench bottom 212. In this example, the
opposing side walls 208 and 210 are parallel with each other and
perpendicular to the trench bottom 212. In this example, the foam
of the trench bottom is manually pierced during installation of hog
rings 204, to maneuver the hog rings below the wire 214. In some
other examples, slots or other apertures (not shown) are provided
in the trench bottom, through which the wire is exposed for
hooking. While the hog rings in this case are shown extending
through apertures 110, in some cases the strip is provided without
apertures and is manually pierced by the hog rings during
installation. If piercing, the hog rings preferably pierce the
reinforced region of the web, such that the resin in that region
helps to prevent tearing or fraying of the web. Apertures 110 may
be positioned at intervals selected for desired hog ring placement
for a particular application, or they may be provided at repeating
intervals and only certain ones used in any given application. One
advantage of repeating aperture intervals (or not providing any
apertures) is that strip 104 can be manufactured in one style and
provided in spool form for use in several different
applications.
[0090] Hog ring 204 preferably bears against the upper surface of
listing bead 102, as shown, such that the bead directly carries hog
ring load by direct hog ring engagement. Even in cases where the
hog ring does not directly contact the listing bead, the presence
of the bead along the edge of strip 104 helps to strengthen the web
of the strip against hog ring pullout, and also helps to distribute
some of the hog ring load longitudinally along the strip.
[0091] Referring next to FIG. 3, strip 104 may alternatively be
retained in trench 206 by a retainer 302 secured at the bottom of
the trench. Retainer 302 may be, for example, in the form of the
flexible fastener strip described in US 2012/0240364, the contents
of which are incorporated herein by reference. Retainer 302 has
pairs of opposing hooks 304 spaced along its length, defining
therebetween a retention channel that is narrower than a thickness
of the listing bead, which is shown in this example as protruding
from both sides of the strip.
[0092] Retainer 302 can be formed as a continuous longitudinal
extrusion of the profile shown in FIG. 3, and subsequently trimmed
to separate the pairs of hooks if desired. The listing bead 102 is
inserted into the channel and snapped into place under the opposing
heads of the hooks. This insertion method is generally believed to
require less manual manipulation than hog ring attachment, and the
pairs of hooks may be closely spaced and the retainer flexed to
follow a curved trench, such that the edge of strip 104 is secured
along essentially its entire length, with less likelihood of
puckering the outer cover surface. The magnitude of force required
to insert and withdraw the bead can be controlled by modifying the
geometry and dimensions of hooks 304. Preferably the required
insertion force is significantly lower than the force required to
pull the bead from the retainer once engaged. Retainer 302 can be
secured at the bottom of the trench by any of several techniques
known in the art, including by embedding the retainer in foam of
the seat bun as the seat bun is formed.
[0093] Several different listing bead profiles are envisioned. For
example, the listing bead 402 of FIG. 4 has a tapered lead-in
portion 404 extending from the strip edge 406 to an intermediate
shoulder 408 against which one of the hooks 304 of each of the
pairs of hooks of the retainer bears to prevent the engaged listing
bead from being pulled from the retainer. A stop portion 410 of the
listing bead is spaced above shoulder 408 to define a hook head
retention groove 412. Stop portion 410 may be of greater thickness
than lead-in portion 404, to provide a positive and tactile stop as
the bead is snapped into the retainer. In this example, the bead
extends from only one side of the web 104, and the opposite hook
head bears directly on the back side of the strip when snapped in
place. Two-sided beads of such profile are also envisioned.
[0094] At the free edge 406 of the strip, the listing bead 402 has
a severed edge coincident with a severed distal edge of the strip
104. Over the width of the listing bead, and throughout the width
of reinforced region 108, resin contiguous with the bead
encapsulates surface fibers of strip 104 to both permanently bond
the bead to the strip and reinforce the strip against tearing and
flexure. A degree of flexibility reduction may facilitate
manipulation of the strip into engagement. The bead profile and
resin can be selected to not over-stiffen the strip.
[0095] The listing beads of FIGS. 5A and 5B are tapered in
thickness over a distance extending from the edge 406 of the strip,
so as to have a thickness that gradually increases to a maximum
adjacent shoulder 408. In the example of FIG. 5B, the listing bead
extends from both sides of the web, and bead resin may connect the
two bead portions through apertures in the web, as will be
described more fully below. In each case, resin contiguous with
resin of the bead extends above the shoulder, forming a layer
across reinforced region 108 of the web. Where this layer joins
with the bead at shoulder 408 the contiguous resin helps to stiffen
the strip to prevent buckling just above the shoulder of the bead.
Even a slight stiffening of the web just above the bead can
facilitate manipulation of the strip during insertion of the bead
into a retainer, or during hog ring installation.
[0096] The listing bead arrangement of FIG. 5C is similar in
perimeter profile to the one of FIG. 5B, but is formed by folding a
strip longitudinally between two half-beads, such that the distal
edge of the final product is formed at a longitudinal fold 414, and
the strip is of doubled thickness. The two sides of the strip can
be welded or adhered together at the upper end (not shown), or sewn
together such as during attachment to an upholstery seam. Fold 414
may be made at an exposed region of the fabric strip between the
two molded bead halves, or along a relatively thin section of
molded resin.
[0097] Referring next to FIG. 6, apparatus 600 includes an extruder
602 with a segmented die producing separate flows, a forming roll
604, a pressure roll 606, a transfer roll 608, and a fourth roll
610. Fabric 603 is a flexible substrate that is fed into the
apparatus from a supply spool (not shown) and threaded through the
nips between rolls, as shown. For ease of view, only the outer
portions of each roll are shown. At least rolls 604, 606 and 608
are normally driven in counter-rotating fashion.
[0098] The outer surface of the forming roll 604 defines multiple
bead molding channels 620, each extending circumferentially about
the forming roll and shaped to form a pair of adjacent listing
beads of desired profile. The molding channels 620 are spaced apart
from one another along the axis of rotation of forming roll 604.
Other than for the molding channels 620, the outer surface of
forming roll 604 may be smooth and cylindrical, as are the outer
surfaces of the other rolls. Some roll surfaces, such as the
surface of roll 606, may be textured or knurled for grip, or made
of a compliant material such as a hard rubber. To keep the
substrate spread out laterally as it enters the process, the
substrate may be trained about a spreader roll 611. Molten resin
612 is introduced from extruder 602 in separate flows into the nip
614 between rolls 604 and 606, the flows each aligned with a
corresponding channel 620 of the forming roll. In nip 614, the
resin is laminated to the surface of fabric 603 and shaped to form
listing bead pairs. The formed resin is cooled while on forming
roll 604, and then stripped from roll 604 with fabric 603 at the
nip between rolls 604 and 608. The laminated product 616 is passed
through another nip between rolls 608 and 610, where the formed
resin beads can be adjusted as needed, and then either slit and cut
into separate strip lengths, or spooled for transport.
[0099] The molten resin 612 can be one of various suitable
materials capable of bonding to the web surface, either chemically
or mechanically upon solidification, and retaining the formed bead
shape. Suitable materials include, for example, thermoplastic
materials, such as polypropylene, polyethylene, and polyamides. In
some cases, the resin is chosen to promote bonding to a particular
substrate material. Furthermore, different materials can be
introduced to different molding channels 620 depending on the
desired fastener product characteristics (e.g., rigidity, hardness,
etc.). Other details of controlling lamination of resin to fabric
under pressure in nips can be found in U.S. Pat. Nos. 5,518,795,
6,202,260 and 7,048,818, the entire contents of which are
incorporated by reference herein.
[0100] Referring also to FIG. 6A, sufficient resin 612 is
introduced to each channel 620 in nip 614 to fill the channel and
extend a distance beyond each edge of the channel along the fabric
603 to form the reinforced regions 108. Across the channel and
within the reinforced regions on either side of the channel, the
resin impregnates the fabric such that when it solidifies it
becomes permanently and mechanically secured to the fabric surface.
Because there is no feature of the mold roll surface constraining
the edges of the resin in the reinforced regions, the reinforced
regions will typically exhibit some width variation along the
resulting strips. Such width variation, within reason, does not
impede product utility or performance. Referring next to FIG. 7,
the laminated continuous sheet 616 includes multiple molded and
longitudinally continuous resin lanes 702, each lane 702 including
a pair of adjacent listing beads 102 joined along a slitting
channel 704. The sheet 616 can be severed along the slitting
channels 704 and midway between the resin lanes 704 to produce
several separate strips each carrying a molded listing bead 102
extending along a severed longitudinal edge thereof. Each resulting
strip may be employed as the fabric strip 104 sewn into the cover
of FIGS. 1-3. Such a process can provide particularly low
production costs.
[0101] Penetration of the moldable resin into the fabric can be
varied for different effects and purposes. For example, in the
continuous sheet product 800 shown in FIG. 8, the molded resin
fills apertures 804 in the fabric and forms exposed resin areas on
the back side of the fabric. In this case the flexible fabric or
substrate 802 is introduced into the nip with apertures 804 aligned
with the molten resin and molding grooves. The pressure in the nip
forces the resin into the apertures 804 and into contact with the
surface of the pressure roll. The listing beads 102 are strongly
attached to the flexible substrate 802, due in part to the resin in
the apertures 804.
[0102] Some profile beads are not formed with slitting channels.
For example, the product of FIG. 9 is formed by a method similar to
that described above, but in which each molding groove forms a
single profile bead with a tapered section 810 ramping from a
narrow edge 812 to a shoulder 814. By cutting this product along
parallel lines 816, separate tie-downs like the one shown in FIG. 1
can be formed. Cutting through the substrate 603 at lines 816
creates severed substrate edges aligned with the narrow edges 812
of the profile beads.
[0103] Extrusion fluctuations and variations in the density or
structure of the substrate can cause the width of the reinforced
region of resin to fluctuate. This can be particularly true when
molding onto fabric substrates. Such width variation can be reduced
by incorporating a small circumferential groove about the mold roll
(e.g., roll 604 in FIG. 6), spaced from the profile bead molding
groove and positioned to correspond with the inboard edge of the
reinforced region. Fluctuations in nip pressure cause the edge
groove to be filled to varying degrees while the visible edge of
the formed reinforcing region remains relatively linear. On the
product the result will be a longitudinal rib spaced from the
molded profile bead, such as rib 818 in FIG. 10. The size of the
rib shown in this figure is exaggerated for illustration. It is
believed that the groove forming this rib acts as an accumulator
for resin laterally displaced in the molding nip. More details on
the use of such edge ribs in forming laminated fastener products
can be found in U.S. patent application Ser. No. 13/804,082, filed
Mar. 14, 2013 and entitled Forming Laminated Touch Fasteners, the
entire contents of which are hereby incorporated by reference.
[0104] The example of FIG. 10 also contains other features that may
be combined in suitable applications. For example, a reinforcing
rim 820 is provided about aperture 110, providing a thicker section
for receiving and holding a hog ring. The resin forming a series of
rims 820 is molded in appropriately shaped recesses on the surface
of the molding roll as the profile bead is formed, and the
apertures 110 are punched through the resulting molded plateaus to
create rimmed apertures. The rim may extend about the entire
circumference of the aperture and be spaced from shoulder 814 of
the profile bead, as in FIGS. 10 and 10A, or the aperture can be
formed immediately adjacent the shoulder as in FIG. 10B, creating a
wide shoulder for a hog ring or other mating clip to bear directly
against. Also, profile bead 822 is reinforced with a continuous
fiber or wire 824 completely encapsulated within the resin. Wire
824 strengthens the bead against loads applied by hog rings or
other mating clips, helping to distribute clip loads along the
length of the bead. Wire 824 may be of metal or a particularly
strong fiber.
[0105] It is desirable, such as to maintain consistent nip pressure
and visibly straight edges of the resin on the substrate, to
maintain a relatively constant effective cross-sectional area of
the molding grooves and other recesses at all circumferential
locations about the molding roll. Thus, at discrete locations where
additional resin is to be formed into an aperture rim or other
projecting structure, it may be desirable to reduce the
cross-sectional area of other portions of the forming recesses. In
the example of FIG. 10, the cross-sectional area of rib 818 is
reduced (or eliminated) where rim 820 is formed, to keep the
overall molding cross-sectional area relatively constant.
[0106] In the example of FIG. 11, the entire profile bead is
segmented, with longitudinally discrete profile bead segments 826
spaced apart along the edge 406 of the substrate. To keep the
molding flow area relatively constant, a raised resin pad 828 is
molded in alignment with the space between adjacent profile bead
segments 826 and spaced from edge 406. Pad 428 is of essentially
the same transverse cross-sectional area as the profile bead.
Segmenting the profile bead helps to maintain flexibility of the
substrate edge, and can be particularly useful in applications in
which a tie-down is to be bent to follow a trench with a relatively
sharp bend. If apertures 110 are to be provided for hog rings, they
should be positioned in alignment with profile bead segments.
[0107] In the example of FIG. 12, the profile bead is in the form
of profile bead segments 826 that alternate between the two sides
of the substrate 603 along the substrate edge, with the spaces
between adjacent segments 826 on one side aligned with the segments
826 on the other side. In this manner, the molding flow area
remains relatively constant and the product maintains enhanced
flexibility. Furthermore, apertures 110 can be placed in alignment
with segments on either side of the substrate. The segments formed
on the side of the substrate facing away from the molding roll in
the nip can be formed in recesses provided in the opposing roll,
and from resin pressed through apertures 830 in the substrate.
[0108] Profile beads can be formed on both sides of fabric strips
in various ways. Referring back to FIGS. 6 and 8, in one example
the outer surface of pressure roll 606 is provided with molding
grooves similar to those of mold roll 608, and the resin and
apertures 804 are such that pressure in the molding nip forces
sufficient resin through apertures 804 to form a similarly profiled
lane of resin on the back side of the fabric, such that continuous
listing beads on both sides of the resulting strips are formed of
the same flow of resin and are connected by contiguous resin
extending through apertures 804. Depending on the molding
conditions, it may be necessary to hold the fabric taut widthwise
as it passes through the nip.
[0109] FIG. 13 illustrates an alternate method of forming strips
with listing beads on both sides of the strips. In apparatus 900
the outer surface of pressure roll 902 defines retention channels
that receive profiled resin lanes of a previously laminated sheet
616 as roll 902 carries the sheet into the pressure nip 614.
Additional resin 612 is introduced to nip 614, to a side of the
sheet opposite the already formed resin lanes 702, thus forming
identical resin lanes on the opposite side.
[0110] FIG. 14 illustrates yet another method of forming two-sided
listing beads. Apparatus 1000 includes a first mold roll 604 as
described above, and a second mold roll 1002 defining a second
pressure nip 1010 in cooperation with the first mold roll 604.
Second mold roll 1002 similarly features molding channels. A second
extruder 1004 extrudes resin 1008 in multiple, spaced apart flows
into pressure nip 1010, forcing resin into the molding recesses of
roll 1002 to form profiled lanes of resin on a face of sheet 616
opposite lanes formed in nip 614.
[0111] Produced by any of the above methods, the two-sided sheet
1012 of FIG. 15 features a plurality of double-sided resin lanes
1102, each forming a pair of double-sided listing beads 1104 and
double-sided reinforced regions 1106. Such a sheet can be split
along slitting channels 704 and midway between adjacent lanes 1102
to form separate strips, each having a double-sided listing bead
along an edge as shown in FIG. 5B, for example.
[0112] Materials formed by the above processes can have uses beyond
securing covers over cushions. For example, the top edge 1202 of
the lightweight curtain 1200 of FIG. 16 carries a listing bead 102
and has a reinforced region 108 with resin contiguous with the
bead. Apertures 110 receive hooks 1204 to hang the curtain from a
rod. The curtain may be formed entirely out of a continuous length
of product formed on the apparatus of FIG. 6, using a lightweight
non-woven material for the substrate and laminating the bead and
reinforcing resin directly onto the substrate. Alternatively,
narrow strips of product 104 (FIG. 1) can be slit from a wide sheet
and then sewn along an edge of a non-woven or other curtain
material. In either arrangement, the bead and the resin in the
reinforced region help to strengthen, and slightly stiffen, the
upper edge of the curtain. Strips of fabric carrying listing beads
and reinforcing resin can also be employed for other uses. For
example, strips of the fabric cut so as to have centrally located
listing beads can be used as stays within apparel. In the garment
of FIG. 17, stays 1302 carry beads 102 that act as stiffening ribs,
and are sewn directly into the garment to provide a desired shape
and/or stiffness.
[0113] The above processes can also be employed to form a resin
bead along the edge of a flexible fabric panel cover. Referring to
FIG. 18, fabric cover 1402 has an edge bead 1404 secured to an edge
of the cover and forming a hook that retains the cover to an edge
of a rigid panel 1406, such as a sheet metal panel. Bead 1404
defines a crook that receives the edge of the panel, such as when
the cover is resiliently stretched. Bead 1404 may be segmented, as
discussed above, but for many flexible covers a continuous bead may
produce a neater edge appearance and hold the cover against
wrinkling. Two such cover beads may be produced by first molding a
preform strip having a straight or canted flange, and then
deforming the molded flange to form a crook. As shown in FIG. 19, a
double-bead preform strip can be molded with canted flanges 1408
extending from a common base 1410 by providing the mold roll with
an appropriately shaped set of nesting molding rings, including two
inner rings 1412 with circumferential surfaces shaped to form the
upper side of flanges 1408, sandwiched between two outer rings 1414
with axial protrusions 1416 that extend about the inner rings to
form the undersides of the flanges. Referring to FIG. 20, the
resulting laminate can be slit between flanges 1408 along line 1418
to form two separate edge beads on separate fabric covers.
Alternatively, prior to slitting the flanges can be plastically
deformed toward the base to deepen their crooks, as shown in FIG.
21, such as by a force applied in the direction of arrow F.
Referring also to FIG. 6, such deformation can be performed
immediately following formation of the preform strip, by
appropriately configuring the nip between rolls 608 and 610. For
example, roll 610 may be configured with shaped grooves that
receive the flanges and bend the flanges toward the base under
pressure, preferably while the molded flanges retain some heat from
molding.
[0114] The listing bead profile may assume various shapes, and the
profile shape need not be continuous along the edge of the strip
for some applications. Referring next to FIG. 22, tie-down 1500 has
an overmolded listing bead 1502 of which the edge portion forms a
continuous rail 1504 along and encapsulating the fabric edge, and
which includes discrete clip receivers 1506 at spaced intervals and
extending inboard from rail 1504. Each clip receiver 1506 has a
leading face 1508 coplanar with the tapered side of the rail but
that extends farther away from the edge and terminates at a
shoulder 1510. An upper flange 1512 is spaced from the shoulder so
as to define a longitudinal recess 1514 into which the mating clip
cam surfaces snap during installation.
[0115] Referring also to FIG. 23, the underside surface 1516 of
flange 1512 functions as a stop surface against which the upper
surface 1518 of resilient clip fingers 1520 bear as the listing
bead is pressed into the clip beyond the point at which full
engagement has been realized. The upper surface 1522 of the flange
is significantly wider than the listing bead rail and is readily
engaged with an operator's fingers to press the clip receiver into
full engagement with the clip. That flanges 1512 are present only
at locations along the tie-down where clips are located can help
the operator quickly locate the clip receivers for rapid and blind
engagement. During engagement, the leading faces on either side of
the lower portion of the clip retainer, in cooperation with the
canted upper faces 1518 of the clip fingers, help to guide the clip
retainer into centered alignment with the clip. Further pressure at
the upper flange surface 1522 spreads the clip fingers apart until
their cam surfaces snap over the shoulders on either side of the
clip retainer. If necessary for repositioning, the clip fingers can
be manually pried apart or otherwise separated, to allow the clip
retainer to be released.
[0116] As shown in FIG. 23, the listing bead rail 1504 in this
example completely envelops the lower edge of the fabric substrate
of the tie-down. Such a rail can be overmolded in an extrusion
process, for example. Discrete clip receivers can be individually
injection molded along the substrate, such as by methods and with
machines known from the manufacture of zippers and the like.
Alternatively, the profile of the clip receiver can be formed as a
continuous extrusion, with material later removed from between the
locations where the clip receivers are to remain. Or the clip
receivers can be formed as discrete resin components and
permanently fastened over the edge of the substrate, as illustrated
in FIG. 24. In that example, an injection-molded clip receiver 1524
is molded with a notch 1526 at which the receiver can be
plastically flexed to clip over the edge of substrate 603, with
molded resin protrusions 1528 of one side of the receiver passing
through apertures in the substrate and into holes 1530 of the other
side of the receiver, where the pins are sonically welded to form a
clip retainer permanently fastened to the substrate, as shown in
FIG. 25. In this example, the listing bead does not include a
continuous rail, and the distal edge of the substrate is free of
listing bead resin in the spaces between clip retainers. Other
means of securing retainer clips to the substrate are also
envisioned, including adhesives.
[0117] A number of embodiments of the invention have been
described. Nevertheless, it will be understood that various
modifications may be made without departing from the spirit and
scope of the invention. Accordingly, other embodiments are within
the scope of the following claims.
* * * * *