CA2097727C - Refastenable mechanical fastening system and process of manufacture therefor - Google Patents

Abstract

The invention is a refastenable mechanical fastening system, made of free formed prongs (22) joined to a substrate (24).
The prongs (22) taper and are nonperpendicularly oriented relative to the plane of the substrate. The prongs (22) also have an azimuthal angle relative to the machine direction of the substrate. Each prong (22) has an engaging means (30) projecting laterally from the periphery of the prong. The free formed prongs are manufactured by the process of depositing liquid material onto a moving substrate, stretching the liquid material in a direction parallel to the plane of the substrate, severing the stretched material to form the distal end and engaging means of the prong, and imparting an azimuthal angle to the prong. The advantageous usage of the fastening system in an article of manufacture, such as a disposable absorbent garment, specifically a diaper, is also disclosed.

Description

WO 92~10957 ! ' 2 0 9 7 7 2 7 P ~tus9t/09462 REFASTENABLE MECHANICAL FASTENING SYSTEM AND
PROCESS OF MANUFACTURE THEREFOR

FIELD OF THE TYVENTTON

The present invention relates to refastenable ~echanical fastening systems, more particularly to fastening systems naving free formed prongs and the process of manufacturing such fastening LO systems.

BA~r.GROUND OF THE INVf~TlON

Refastenable mechanical fastening systems are well known in the art. Typically, such fastening systems involve two major cosponents, a prong which is joined to a substrate and engages with a complementary second component, the receiving surface. A
projection of the prong of the fastening system penetrates the receiving surface and either engages or intercepts strands or fibers of the receiving surface. The resulting mechanical intelferf ~ and physical obstruction prevent removal of the fastening system from the receiving surface until the separation :
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forces exceed either the peel or shear strength of the fastening SrSt~.

Presently refastenable mechanical fastening systems are made by at least two general methods. One method requires a plurality of filaments each of which may be formed into two prongs.
Examoles of fastening systems producDd by this method are shown in U.S. Patent Ho. ~ 71~ 437 issued SePte~ber 13 l9S5 to de Mesteral and U.S. Patent No. 3 g43 981 issued March 16 1976 to 0 De Brabandar which teach a raised pile of loops. Related téachings are shown in U.S. Patent No. 4 216 257. issued August 5 1980 to Schams et al. U.S. Patent No. 4 45~ 183 issued June 12.
158~ to ~ollman and U.S. Patent No. 4 ~63 ~86 issued August ~
1984 to Matsuda. These refe.erces te-ch heating the ends of polymeric monofilaments. Other related teachings of fastening syste~s produced by the first method are d1sclosed in U.S. Patent No. 4 307 493 issued December 29 1981 to Ochiai and U.S. Patent No. 4 330 907 issued May 25 1982 to Ochiai.

The second general method commonly utilized to manufacture mechanical fastening systems is to mold or e~L~e the systems as illustrated in U.S. Patent No. 3 147 528 issued September 8 1964 to Erb and U.S. Patent No. 3 594 863 issued Ju1~ 27 1971 to Erb.
Contlnuous inject10n moldlng is taught in U.S. Patent Ho.
3 ~9~ 86~ issued July 27 1971 to Erb.

Various prong structures are illustrated in the prior art.
For example the refe~r~es dlscussed a~ove teach fastening s~ste~s having stems af generally constant cross sectlon. U.S.
Patent No. 3 7û8 833 issued Jar~ y ~ 1973 to Riblch et al.
d1scloses a prong which is somewhat tapered from the proximal end to the dlstal end and p_.p~ itcularl~ projects from the substrate.

European Patent Application Ho. 0 276 970 flled January 26 1988 by the Procter ~ Gamble Company in the nane of Scripps dlscloses a fastening device having a constant cross section stem oriented at an angle between a~out 30- and about 90- relatlve to the base.

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~ wo 92/1OsS7 2 ~ 9 ~ ~ 2 ~ PCrJUS91/os462 The prior art does not sho~ methods of ~anuf~cture which prodace free formed prongs. The pr10r art also does not sho~ t~e structure of a mechan1cal fastening system ~nerein the prong is n rFe~ r ~nd1cu1arly oriented rel-t1ve to the substrate and hts ; tapered sides. The prior art also does not sho~ methods of manufacture which produce free fonmed prongs oriented substantially in the cross-machine direction of the substrate.

It is an object of this invention to provide a free formed o mechanical fastening system p~c ~ed by a method of manufacture similar to g~avu~e print1ng. It is also an object of this invention to provide a fastening syste~ having tapered prongs which do not perpcrdtcularly project fro~ the associated substrate. It is a further object of this inventton to provide a fastening system having free formed prongs which are oriented substantially in the cross-machine dtrect10n of the substrate.

BRIEf SUMMARY OF THE ~NVE~TION
The invention comprises a fastening system for attaching to a comple~entary receivtng surface. The fastening system has a substrate and at least one free formed prong comprising a base shank and engaging means. The base of the prong is joined to the ~5 substrate and the shank is conttguous with and projects out~ardly from the base. The engagtng means is joined to the shank and projects laterally beyond the peripher~ of the shank. The shank is nonperpendicularly oriented relative to the plane of the substrate. The shank has a leading edge and a trailing edge deftning a leadlng angle and tratl1ng angle respective7y. The leadtng angle and tra11tng angle are substant1ally dtfferent from each other so that the sides of the shank are nonparaltel. The shank also has an azimuthal angle. The a~t~uthal angle can be bet~een about I- and about 180- preferably bet~een about 20- to about 160- relattve to the MO.

The fastenlng system may be made accordtng to the process comDrtsing the steps of heattng a then~ally sens1t1ve material sufftctentlr to reduce tts viscositr for processing and prefenbly to at least 1ts ~elttng potnt. A ~eans to deposit .
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wo 92/1095~ PCT/US91/09462 discrete amounts of the heated material is provided. The substrate to ~hich the material is to be joined ls transported in a first direction relative to the means for deooslting the material. The mater1al is deposited on the transported substrate in discrete amounts. The dtscrete amounts of material are then stretched in a d1rect10n having a vector component generally parallel to the plane of the substrate. The stretched material is severed to form a distal end and engaging means and an azimuthal angle between about l to about l80- preferably bet~een about 20-o to about 160- is imparted to the shank.

An illustrative and suttable but nonlimitinq use for the fasteninq system p~od~ced by the process of the present invention is in conjunct10n with a disposable absorbent garnent such as a diaper. This example of one usage of the present invention is more fully descr1bed belo~.

BRIE~ DESCRlPTrON Of THE ~RA~THGS

~hile the Spec1f1catlon concludes wlth claims particularly pointing out and d1st1nctly claiming the invent10n it is believed the invention will be better understood from the following descript10n taken in conjunct10n with the associated drawings in which like elements are described by the same refe~ ee numeral and related elements are designated by adding one or more prime symbols or increment1ng the numeral by lO0:

Figure l is a p~r~e~ttve vie~ of a fastening syste of the present invent10n wherein the engaging means are oriented in substant1ally the same direct10n;

Figure 2 is a side elevat10nal view of one prong of the fastening system shown in Figure l;

Figure 3 is a side elevational view of a second e~bodiment having a generally semispherically shaped engaging means;

Figure 4 is a side elevational schematic view of one apparatus , . :
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Figure S is a perspective view of a fastening system of the present invention wherein the engaging means are oriented in substantially random directions;

Figure 6 is a pe~spec~ive vie~ of a disposable abSorDent garment utilizing the fastening system of the present invention o showing the topsheet and core partially in cutawa~;

Figure ~ is a top plan view of one prong having an azi~uthal angle of about 90 ;

Figure 8 is a front elevattonal vie~ of one apparatus (only a portton of which is shown) wnich can be used to produce the fastening system of the present inventton having az1muthally angled prongs;

figure 9 is a top p1an vie~ of a second apparatus which can be used to produce the fastening system of the present invention having azimuthally angled prongs OETAILfn DESCRrP~ION OF THE IHVENTION
~5 The fastening system 20 of the present invent10n co0prises at least one prong 22 and prefe~ tly an arra~ of prongs 22 joined to a suhstrate 24 in a predetenmined pattern as sho~n in Figure 1 The prongs 22 have a base 26 shank 28 and engaging me-ns 30 The bases 26 of the prongs 22 contact and adhere to the substrate 24 and support the proxtmal ends of the shanks 28 The shanks 28 projeet out~ardly from the substrate 24 and b-ses 26 The shanks 28 terminate at a dista1 end whtch is joined to an engaqtng means 30 The engagtng means 30 rad1-11y projeet laterall~ from the shanks 28 in one or more directtons and may resemble ~ hook-shaped ttne As used herein the term ~l~teral~ me-ns having a vector co~ponent generally parallel to the plane of the substrate 2~ at the prtnctpal prong 22 under cons1deratton The projectton of an engaqing means 30 from the shank 28 periphery in a lateral dtrectton allo~s the engagtng oc~ns 30 to be se0red to a :, . ' ~ . . ~

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W092/lOQ57 9~r ?~ PCTJUS91/09462 t co~plementar~ receiving surface (not sho~n). The engaging 0eans 30 1s joined to and preferabl~ conttguous with the distal end of the prong 22. It will be apparent the engaging means 30 mar be joined to the prong Z2 at a positton ~ n the base 26 and the s distal end of the shank 28.

The arra~ of prongs 22 may be p~oduced by any suitable method includins methods which yietd a free formed prong 22 as described and claimed hereinbe10w. As used herein the term ~free o formed~ means a structure whtch is not removed from a mold cavity or extrusion die in solid form or with a defined shape. The prongs 22 are deposited onto a noncontiguous substrate 24 in a molten p~efe~a ly liquid state and solld1fy by cooling until rtgid and preferably ~reez1ng into the desired structure and shape as described hereinafter.

The free formed array of prongs 22 is prefe~ably p~od~ced by a manufacturing peocess which is similar to that process commonly known as gravure prtnt1ng. Using this process a substrate 24 h-ving opposed faces is passed between the nip 70 of two generally cylindrical rolls a print roll 72 and a backing roll 74 as illustrated at Figure 4. The rolls 72 and 74 have generally parallel centerllnes and are m~intained in contact1ng relationship with the su~strate 24 as it passes through the nip 70. One of the 2S rolls refe... ed to as the print roll 72 has an array of blind.
closed-end cavtt1es refe.ned to as cells 76 cG.-espon~tng to the desired pattern of prongs 22 to be deposited on the substrate 24.
rhe second roll ~efe~ned to as the backing roll 74 provides the react10n against the print roll 72 to posit10n the substrate 24 against the prtnt roll 72 as the substrate 24 passes through the nip 70. Liquid ~ thermally sensitive material p~ererably thermopl~sttc saterial from which the prongs 22 are to be for~ed is suppliêd from a heated source such as a trough 80. rhe thermall~ sensittve material is inl~ ed into the cells 76 as the print roll 72 is rotated about its centerllne. The ce11s 76 containing the then~lly sensit1ve material transport it until contact ~1th the substrate 24 is made and depos1t th1s ~terial onto the substrate 2~ in the desired pattern.

, W O 92tl0957 2 0 9 7 7 2 7 pcr~us91/os462 As relative dlsplacement betl: er the substrate 24 and rolls 72 and 74 cont~nues the prongs 22 are stretched with a latera1 component generall~ parallel to the plane of the substr-te 24 forming the shank 28 and the eng-ging means 30. Finally the moil of the prong 22 is severed from the engaging means 30 by a severing means 78. Due to the viscoelastic properties of the thermoplastic. the prong 22 contracts. ~t is also believed that ~he prong 22 retracts under the influences of gravity 2nd shrinkage which occur during cooling. The prong 22 then cools o and preferab1y freezes into a solid structure having the engaging means 30 contiguous with the shank 28.

The fasteninq system 20 is secured to a comD1ementary receiving surface. As used herein the term ~receiving surface~
to which the engaging mrans ~0 of the fastenin~ system 20 are secured refers to any p1ane or surface having an exposed face ~ith tightly spaced openings conplementary to the engaging means ~ and defined by one or more strands or fibers or alternatively ~hich exposed face is capable of local k ed elast1c deformat10n so that the enqaging means 30 may become entrappEd and not withdra~n without inte~fe~e~ e. The openings or locali2ed elastic defo. 7tions allow ~or entry of the engaging means 30 into the plane of the receiving surface while the strands (or nondeformed material) of the receiving surface interposed betl~en the openings (or deformed areas~ prevent withdrawal or release of the fastening system 20 until desired by the user or either the peel or shear strength of the fastening systêm 20 is otherwise exceeded. The plane of the receiving surface may be flat or curved.

3a A receiving surface having strands or fibers is said to be ~complementary~ if the opentngs b2~u e strands or fibers are sized to allow at least one engaging means 30 to penetrate into the plane of the receiving surface and the st._ris are sized to be er~a3~i or intercepted by the engaging means 30. A receiving surface which is loca11y deformable is said to be ~complementary~
if at least one engaging means 30 is able to cause a localized - distu.L--ee to the plane of the receiving surface ~hich dtsturL~~ee resists re~oval or separation of the fastening system 20 from the receiving surface.

WO 92tlO957 9~ 7 PCT/US91l09462 ~

Suitable recetving surfaces include rettculated fo~ms kn~tted fabrics rQ ~en m~terials and stit~htcn~ed loop ~aterials such as Velcro brand loop m~ter1als sold br Velcro USA
of Hanchester Hew H~moshire. A particularly suitable receiYing surface is stit-hbond~d fabric Number 970026 sold by the Milliken Company of Spartanburg South Carolina.

Referrin~ ~ck t~ Figure 2 to examine the components of the fastening system 20 in more detail the substrate 24 of the o fastening system 20 should be strong enough to preclude tearing and separatton between individual prongs 22 of the fastening system 20 be a surface to wh1ch the prongs 22 will readlly adhere and be capable of being joined to an artlcle to be secured as desired by a user. As used herein the term ~join~ refers to the condition where a first member or co0ponent is affixed or connected to a second me~oer or co~ponent either directly; or indirect~y where thc first me~ber or co~ponent is affixed or connectéd to an inter~ediate member or co~ponent which in turn is affixed or connected. to the second _ ber or component. ~he association between the first member or component and the second member or component is intended to re~in for the life of the article. The ~substrate~ is an~ eYvosed surface to which one or more pronqs 22 are joined.

2j The substrate 2~ should also be capable of being rolled to support conventional ma~f~.-u.ing processes flexible so that the substrate 24 ma~ be bent or flexed in a desired configuration and able to withstand the he~t of the liquid prongs 22 being deposited thereon without melting or incurring deleterious effects until such prongs 22 freeze. The substrate 24 should also be available in a variety of widths. Suit~ble substrates 24 include knitted f~brtc wo~en ~ter1als 1 ~ven materials rubber vinyl fil~s p~rttcularly polyolefinic filws and preferably kraft paper. ~hite kraft p~per having a b~sis weight of 0.08 kilogr-ms per square meter (50 pounds per 3 000 square feet) has been found suitable.

The b~se 26 is the generally planar portion of the prong 22 which is attacbed to the substrate 24 and is contiguous with the proximal end of the shank 28 of the prong. As used herein the ter~ ~base~ refers to that portion of the prong 22 which is in ' :
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w o 92rlogs7 2 0 9 7 7 2 7 PCT/US91/09462 direct contact with the substfate 24 and supports the shank Z8 o~
the prong 22. It is not nesetsary that a demarc3tlon be apparent between the base 26 and the shank 28. It is only 1mportant that the shank 28 not separate from the base 26 and that the base 26 not separate from the substrate 24 during use. The base 26 cross section should provide sufficient structural integrity and hence area for the desired peel and shear strengths of the fastening system Z0 based on the density of the pattern of prongs 22 and length of the shanks 28 of the individual prongs 22 and further o provide adequate adhesion to the substrate Z4. If a ~onger shank 28 is ut11ized the base 26 should generàlly be of greater cross sectional area to provide sufficient athesion to the substrate 24 and adequate structural integrity.

The shape of the footprint of the base 26 on the substrate 2$
is not critica1 and may be am4lified in any direct10n to provide greater structural integr1ty and thus a greater peel strength in that direction. As used herein the term ~footpr1nt~ refers to the planar contact area of the base 26 on the substrate 24. The aspect ratio of the sides of the footprint should not be too great otherwise the prong 22 may be unstable when subjected to forces parallel to the shorter side of the footpr1nt. An aspect ratio of less than about 1.5:1 is preferred and a generally circular footprint is more prefer.ed.
For the embodiment described herein. a base 26 having a footprint of generally circular shaDe and approximately 0.76 mi11imeters to 1.27 milli~eters (0.030 to 0.050 inches) in diameter is suitable. If it is desired to make the fastening system 20 have a greater peel or shear strength in a part1cular d1rect10n the cross sectional area of the base 26 may be modified to amplify such direction so that the strength and structural integr1ty relative to the axis orth~g~nal to such direction increases. This modification c~uses the prongs 22 to be stronger when pu11ed in the amplified d1rection of the base 26.

The shank 28 is cont1guous with the b-se 26 and projects outwardly from the base 26 and substrate 24. As used herein the term ~shank~ refers to that portton of the prong 22 which is intermediate of and cont19uous with the base 26 and the engaging . ' .

Wo 92/1OsS7 ~ ~ 9 ~ ~ ~ pcr~usg1/o9462 means 30. The shank Z8 provides longttud1n-1 spac1ng of the engag1ng ~eans 30 from the substrate 24. As used herein the term ~longitudtn~l~ means in a dtrectton having a vector component awa~
from the substrate 24 which dtrectton increases the perpendtcular distance to the plane of the substrate 24 at the base 26 of the prong 22 unless otherwise specified to be a direction having a vector co~ponent towards such plane of the substrate 24.

Associated with the shank 28 and base 26 of each prong 22 is lo an origin 36. The ~origin- of the shank 28 is the point which may be thought of as the center of the base 26 and is typically within the footprint of the base 26. The origin 36 is found by viewing the prong 22 fro~ the stde view. The ~s1de view~ is any direction radta11y towards the shank 28 and base 26 which is also parallel to the p1ane of the substrate 24. If the fastening srstem 20 is manufactured b~ the process described and claimed below it is p~efe..ed but not necessary that the prong 22 be viewed in the machine and cross-machine dtrecttons relative to the travel of the substrate 24 through the nip 70 when deter0ining the origin 36.

The lateral dtstance between the remote edges of the base 26 footprint for the particular side view under consideration is found and this distance is b1sected yielding the midpoint of the base 26 for such view. ~hen bisecting the footprint of the base 26 for the particular side view under consideration minor d~scont1nuittes (such as fillets or asperities incident to the attachDent to substrate 2~) are ignored. Thts point is the origin 36 of the shank 28.

The shank 2B makes an angle ~ with the plane of the substrate 24. As used herein the tenn ~plane of the substrate~ refers to the flat planar surface of the substrate 24 at the base 26 of the principal prong 22 under consideratton. The angle ~ is determined as follows. The prong 22 is vie~ed in prof11e. The ~profile view~ of the prong 22 is one of two parttcular side views and found as follows. The prong 22 is visu~llr inspected fro~ the stde views such that the dtrection havtng the maximum lateral project10n ~8 beco~es apparent. The ~lateral pro~ectton~ is the oo d1stance taken laterally and parallel to the plane of the .

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2~7727 - W0 s2/1oss~ PCTrUS9t/os442 substrate 2~ from the center of the base 26 in such vte~ i.e. the origin ~6 of the shank 28. to the project10n of the furthest laterally re00te point on the prong 22 visib1e in such vie~ ~hen such point is longitudinally and ~e.~ dicul~rly projected d~l ~- r~ to the plane of the substrate 24.

It will be apparent to one skilled in the art that the maximum lateral projection 38 is th~t project10n fro~ the origin 36 to the outer periphery of the shank 2~ or engaging means ~0.
LO The side view of the prong 22 which maximi~es the lateral projection 38 is the profile view of such prong 22. It ~ill also be apparent to one skitled in the art that if the fastening system 20 is ~roJuc~d by the process described and claimed below and if the maxi~un lateral project10n 38 is generaily oriented in the ~achine direction then the profile ~ie~ will be generally oriented in the cross-~chine directton. It ~ill also be apparent that if the maxi~um lateral projection 38 is generall~ oriented in the cross-mach1ne d1rect10n then the prof11e view will be generally oriented in the machine d1rectton. The side elevationa1 view shown in Figure 2 is one of the proftle vie~s of the prong 22. It will be further afp~eAt to one skilled in the art that there is another profile vie~ generally 180- opposite from the profile vie~ shown (so that the maximum lateral projectlon 38 is oriented to~ards the left of the viewert. Either of the two ~5 profile ~ie~s is generall~ equ~lly well suited for the pcocedu~es and usages describet hereinbe70~.

The origin 36 of the sh~nk 28 is found as descrtbed above ~1th the prong 22 in the profile view. ~h11e st111 m~intaining the prong 22 in the profile view an imaginary cutt1ng plane 40-~0 generally parallel to the plane of the substrate 24 is then brought tnto t-ng~r~y with the periphery of the prong 22 at the point or segment of the prong 22 having the greatest pe ~?~tcular d1st~nce from the plane of the substrate 2~. Thts co~espDr - to the port10n of the prong Z2 h~ving the htghest elevation. The imaginary c~tt1ng plane 40-40 is then brought one-fourth of such greatest perpend1cular d1st~nce closer to the su~str~te 2~ from the potnt of highest elevat10n so th~t the i~gin~ry cutt1ng plane 40-~0 intercepts the prong 22 at a SUI~STITUTE StlEET

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longitudinal elevation three-faurths of the perpendlcular distance from the plane of the substrate 24 The imaginary cutting plane 40-40 is then used to determine three points on the prong Z2 The ftrst point is that point where the cutting plane intercepts the leading edge 42 of the prong 22 and is referred to as the 75% leading point 44 The ~leading edge~ is the apex of the periphery of the shank 23 which longitudinally f~ces awa~ from the plane of the substrate 24 The second point is d1s~osed about 180 through the center of the prong 22 and is the point where the cutting plane 40-40 intercepts the trailing edge 46 of the prong 22 and is refe d to as the 75X
trailing point 48 ~he ~trailtng edge~ is the apex of the periphery of the shank 28 wh1ch long1tudinally faces towards the substrate 24 and is generally oppositely disposed from the leading edge 42 The straight line o~r1e t1ng these two points falls of course within the cutting plane ~0-40 and is bisected to yield the midpoint 47 of the imaginary cutttng plane 40-40 A straight line is then drawn connect1ng the midpoint 4~ of the imaginary cutting plane 40-40 w1th the origin 36 of the shank 28 at the base 26 The included angle ~ th1s line defines relative to the plane of the substrate 24 is the angle a of the shank 28 Alternativeiy stated the angle ~ which the shank 28 makes relative to the plane of the substrate 24 is the 90 oomplement of that angle furthest from the p_ p~ndicular defined by the line found in an~ side view connecting the cutting plane midpoint 4~
and the origin 36 Hence the smallest angle relative to the plane of the su~strate 24 when th1s line is viewed in any dtrectton radially towards the shank 28 and particularly the origin 36 whtch d1rect10n is generally parallel to the plane of the substrate 2~ and Grt ~unal to the pe r~n~tcular is the angle of the shank 28 It is to be recogntzed that when a prong 22 having a m xi~u~ lateral project10n 38 oriented in the machine dtrectton is vie~ed approximately in the machtne direct10n or approximatel~ 180 t~ ~efnom or when a prong 22 having a maximum lateral projectton 38 ortented in the cross-machtne direct10n is viewed approximatel~ tn the cross-machine d1rectton the apparent angle ~ of the shan~ 28 will be about 90 HoweYer as discussed above the angle ~ to be ~easured is that whtch dev1ates furthest wo 92J10957 2 0 9 7 7 2 I pcT/us9l/n9462 from the perpendlcular and therefore. is generall~ that angle ~
detenmined ~hen the prong 22 is viewed 1n profile typ1cally from about the cross-machine directlon for a prong 22 oriented in the machine direction. and from about the machine dtrect10n for a Dronq 22 oriented in the cross-machine direction.

The angle ~ of the shank 28 may be generally perpendicular to the plane of the substrate 26 or is prefe.ably oriented in an acute angular relation re1ative thereto to provide increased peel strength in a particular directlon which direction is qenerally parallel to the maximum longitudinal projectton 38. l~ ~er the angle Q of the shank 28 should not deviate excessively from the perpsndicular otherwise a fastening system 20 of more directionally specific shear strength results. For the embodiment described herein a shank 28 having an angle Q bet~een about 45-and about 80 preferably about 65- works well. If the angle of the shank 28 is less than ab;out 80- the shank 28 is considered to be n~rp7. ~dicu)arly oriented relative to the plane of the substrate 24 (without regard to lateral orientation).
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The imaginary cutt1ng plane 40-40 and prof11e view can also be utilized to determine the angles of the lead1ng edge 42 and the trailing edge 46 relative to the plane of the substrate 24. To determine these angles the 7SX lead1ng point 44 and 75X trai1ing ~5 point 48 are found as described above. The base 26 leading point 50 is found as follows. ~he line through the base 26 as viewed in prof11e is brought to intersect the leading edge 42 of the shank 28. This intersection is the ~base 1eading point.~ As noted above minor discont1nuities in the sh-nk 28 near the base 26 incident to attachment to the substrate 24 are not considered when detenmining the base lead1ng point 50. The 7~X leading edge 42 point is connected by a straight line to the base leading edge 42 point. This straight line fonms an included angle ~L relative to the plane of the su~ trate 24 and opening in the d1rect10n of the origin 36 and center of the shan~ 28. The angle ~ ts referred to as the angle of the leading edge 42 or simply the lead1ng edge angle.

The base trailing point 52 is generally d1sposed 180- from the base leading point 50 thro~gh the center of the base 26 and wo 92~10957 9~ ~h7 PCr/US91/09462 ' ~4 found as follo~s. The line throu~h the footprtnt of the base 26 as vie~ed in profile is brought to intersect the tratling edge ~6 of the shank 28. Thts intersection is the ~base trailing point.~
As noted above minor disconttn~ities in the sh~nk 28 near the S base 26 inc1dent to attachment to the substrate 24 are not considered when determining the base trailing point 52. As described above the 75% trailing point 48 is connected with the base trailing point 52 by a straight line. ~his 5traight line forms an included angle ~T relative to the plane of the substrate 24 and opening in the direct10n of the origin 36 and center of the shank 28. The included angle ~T is ~eferred to as the angle of the trailing edge 46 or simply the trailing edge angle.

The lead1ng edge 42 and trailing edge 46 included angles B~
!5 and ~T define the parallelism of the sides of the shank 28. If the angles ~ and ~r of the leadtng and trailing edges 42 and 46 are not supplementary to each other (do not add to an arithmetic sum of about l80 ) the s1des of the shank 28 are said to be nonparallel. If the s1des of the shank 28 are nonparallel the straight lines which define the angles ~L and ~T (connecting the base lead1ng and trailing points 50 and 52 with the 75X 1eading and trailing po1nts 44 and 48 respectively) intersect either above or below the plane of the substrate 24. If the angles ~L
and ~T of the leading and trailing edges 42 and 46 are unequal and the lines defining such angles intersect above the plane of the substrate 24 (longitudinally outwardly of the base 26) the prong 22 will u ~c~ from the base 26 towards the dlstal end and engaging means 30. On~y if the angles ~ and ~T of the leading and trailing edges ~2 and 46 have the sane sense i.e. are oriented in the same directton and supplementary magnitudes are the angles ~L and ~T of the leading and trailing edges 42 and 46 detenmtned to be equal and the sides of the shank 28 to be parallel.

A shank 28 having a leading edge 42 wh1ch forms a leadtng edge angle ~ w1th the substrate of about 45- + 30- is suitable.
A trtiling edge 46 which forms a trailtng edge angle ~T with the substrate of about 65- + 30- is suitable. A shank 28 having these angles ~ and -~r of the lead1ng and trailing edges 42 and 46 wor~s 4~ ~ell wtth the afore ent10ned spectru~ of included angles ~ of the , WO 92~1095~ 2 0 ~ 7 7 2 7 PCT~US9t~0s462 shan~ 28 to y1eld a ta~ered shank 28 advantaqeousl~ oriented rel~t~ve to the substrate 2~ to provide htgh shear and peel strengths without requiring excesstve prong m~terial.

The foregoing measurements are easily made using a Model lO0-00 1I5 goniometer sold by Rame -Hart. Inc- of Mount~in ~akes.
New Jersey. If more precise measurement is desired it wilt be recognized by one skilled in the art that determination of the profile view origin 36 cutttng plane 40-40. leading angle ~
trailing angle ~T. base points 50 and 52 JS% points U and 48 and the angle Q of the shank 28 can be advantageously performed by making a photograph of the prong 22. A model lJ00 scanning electron mic~se~e sold b~ Amray Inc- of New Bedford Massachusetts has been found to work well for this purpose. If necessary several photographs may be taken to deten~ine the maximu~ lateral projection 18 and hence either profile vie~.

The shank 28 should longitudinally project from the base 26 a dtstance suff1cient to space the engagtng means 30 from the substrate 2~ at an elevat1On which allo~s the engaging ~eans 30 to readily intercept or engage the strands of the receiving surface.
A relatively longer shank 28 provides the advantage that it can penetrate deeper into the receiving surface and thereby allow the engaging means 30 to intercept or engage a greater number of ~; strands or fibers. Conversely a relatively shorter shank 2a length provides the advantage that a relat1vely strongen prong 22 results but also provides :~ ~esponJtngly 1ess pentt~tlon into the receiving surface and may the efore be unsuitable for receiving s~.rcc~s such as ~ool or loosely st1tched bonded m~terials which have less densely packed strands or fibers.

If a kn1tted or woven matertal recetvtnq surface is utilized a retat1vely shorter shank 28 having a long1tudinal length from the substrate 2~ to the point or segment of highest elevation of about 0.5 mitli eters (0.020 inches) prefe~ably at least about 0.7 millimeters (0.028 inches) is suitable. ~f a high loft material rece1vin~ surface havtng a caliper greater than a~out 0.9 millimeters (0.035 inches) is uttlized. a relatively longer shank 28 having a greater longitudinal di~enston of at least about 1.2 millimeters ~0.0~7 inches) ~.ef~ab~y at le-st about 2.0 .

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;' ' W0 92/10957 ~ PCr/US91/09462 milltmeters (0 079 inches~ ls wre suitable As the shank 28 length increases. and shear strength cc es~ond1ngly diminishes thc density of the prongs 22 of the fastening system 20 may be increased to compensate for such loss of shear strength S

As described above the longitudinal length of the shank 2~3 determines the longitudinal spacing of the engaging means 30 from the substrate 2~ The ~longitudinal spacin~ is the least perpendicular d1stance from the plane of the substrate 24 to the periphery of the engaging means 30 For an enqaging means 30 of constant qeometry the 10ngitudin-1 spacing of the engaging means 30 from the substrate 24 becomes greater ~ith increasing longitudinal shank 28 length A longitud1nal spactng of at least about twice the strand or f1ber diameter of the intended receiving lS surface and preferably about 10 times as great as such fiber or strand diameter provides good interceptton or engagement and retentton of such strands or f1bers by the engaging means 30 of the fastening system 20 For the embodiment descrtbed herein a prong 20 having a longitud1na1 spacing of about 0 2 m111imeters to about 0 8 ~111imeters (0 008 to 0 03 inches) wor~s ~ell The shape of the cross seet10n of the sh-nk 28 is not critical Thus the sh~nk 28 m~y be of any cross sectton desired according to the afore~entioned parameters relat1ng to the cross section of the b~se 26 The ~cross section~ is the planar area of any part of the prong 22 taken pe~pendicular to the shank 28 or the engaging means 30 As noted a~ove the shank 28 is preferably tapered to decrease in cross sect10n as the d1stal end of the shank 28 and engaging means 30 of the prong 22 are longitudinally and laterally approx1~ted Th1s arrang _ nt provides a CG~ ~sponiing decre~se in the moment of inertia of the shank 28 and engaging means 30 result1ng in a prong 22 of more near1y constant stress when sep-ratlon forces are awl1ed to the fastening system 20 and thereby d1m1n1shes the quant1ty of superfluous mater1als in~ ated into the prong 22 To m~intain the des1red geometry over a ~1de r-nge of prong 22 sizes a generally un1form ratlo of cross sect1cnal areas can be ut11ized to scale the prongs 22 One rat10 ~h1ch generally controls the over-ll t~per of the prong 22 1s the r~t10 of the ; - wo 92/10957 2 ~ 9 7 7 2 7 PCT/US91/09462 area of the cross sectton of the base 26 to the area of the cross sect10n of the prong 22 at the highest elev~t10n of the prong 22 the phrase ~highest e~eYation~ refers to the th~t polnt or segment of the shank 28 or the engaging means 30 h-vinq the greatest perpendicular dtstance from the plane of the substrate 24 Typically prongs 22 having a base 26 cross sectional area to highest elevation cross sectional area rat10 in the range of about 4 1 to a~out 9 l wor~ well o A generally ~ircular shank 28 which tapers from a base Z6 diameter as d~scussed above ranging from about 0 76 millimeters to about 1 27 millimeters (0 030 to about 0 050 inches) to a highest elevat10n diameter of about 0 41 ~i11imeters to about O Sl millimeters ~0 016 to 0 020 inches) has been found suitable for the embodiment discussed herein Specifically a generally ctrcular shaped cross sectton of about 0 46 mtllimeters (0 0l8 inches) d1ameter at the h1ghest elevat10n provides a cross sect10nal area at highest elevat~on of about 0 17 square millimeters (0 0003 square inches) A gener~lly circular shaped base 26 cross sectton of about 1 0 millimeters (0 040 inches) provides a base 26 cross sectional area of about 0 81 square mtllimeters ( 0013 square inches) Thts structure results in a ratio of base 26 cross sect10nal area to highest elevat10n cross sectional area of about ~ 1 whtch is within the aforement~oned range The engaging means 30 is ioined to the shank 28 and prere ~bly is contiguous with the dtstal end of the shank 28 The ~ ging means 30 projects rat1ally away and outwardly from the periphery of shank 28 and may further have a vector component whkh longitudinally projects i e towards or away fro~ the ~b~t~ee 24 As used herein the term "engaging me~ns~ refers to any protrusion lateral to the per1phery of sh~n~ 28 (other than minor asper1tles in the per1phery of the sh~nk 281 which prctrusion resists separatton or remaval from a rece1vtng su Pace The term ~periphery~ ~eans the outer surface of the prong 22 The term ~radi~lly~ m~ans from or towards the perpend1cular to the su~ trate 24 which ~e~p~ldlcular passes through the ortgin 36 which is generally centered ~ithin the fco~ t of the base 26 -.. . .
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-W o 92~10g57 ~ PCT/US9t~09462 P2rtic~1arly the lateral protrusion has ~ vector c lel~t parallel to and facing towards the plane of the substrate Z~. It is to be recognized that the engaging means 30 and sh~nk 2a may have both lateral and longitutinal vector c ~ en~ t is not ; important that a sharply defined terminus of the sh~nk 28 distal end be apparent or that a demarcation between the shank 28 and engaging means 30 be discernible at all. It is only necessary that a longitudinally oriented face of the shan~ 28 periDherr be interrupted so that the engaqinq means 30 has a faoe with a vector 0 CU ,~F' t parallel to and facing the plane o~ the substrate 2~.

The en~aging means 30 may have a greater lateral projection 38 than the shank 28 or vice-Yersa. as desired- As illustrated in the fiqures the engaging means 30 is prefe~dbly generally l~ arcuate and may have a reentrant curve. If the engaging means 30 has a reentrant curve the engaging means 30 includes a segment which longitudinally approximates the substrate 2~ at the base 26 or a location laterally spaced from the base 26. Thts segment is laterally directed towards the shank 28 although the segment need zo not be radially directed towards the origin 36.

The enqaging means 30 of each prong 22 of the fastening system 20 may laterally extend substant1ally in the same direction if a relatively unidirecttonallY oriented peel strength ~j is desired or may be randomly oriented to provide substantially isotropic peel str~r ~hs in any lateral direction. The engaging means 30 may be hook-shaped tines which project substantially from one site of the shank 28 defininq a ~enerally convex out1ine and penetrate the opening of the receivtng surface to intercept the strands or fibers of the receiving surface at the inner radius of curvature 54 of the engag1ng means 30. The inte.~e~ nce bet~een the engaging means 30 and strands or f1bers of the reeeiving surface prevents release of the fastening system 20 from the receiving surface until the peel strength or she~r strength of the fastening system 20 is P1~eeeded. The engaging means 30 shoult not radiall~ project too far in the lateral directton otherwise the engaging means.30 may not p~r l~ate the opening of the receiving surface. The cross sectton of the engag1ng means 30 should be slzed to pan~trate the opentngs of the receiving surf~ce.

( - WO 92/10957 2 ~ ~ 7 7 2 7 PCr/USgt/09462 .9 The cross sect10nal area and geometry of the enqaging means 30 are not critical so long as the engaging ~eans 30 has structural integrity which provides suffic1ent 5he-r and bendin~
strenqths to accommodate the desired peel and shear stren~ths of a fastening system 20 having an array of pronqs 22 of a given density. For the embodiment described herein a hook-shaped tine engaging means 30 having a maximuo lateral projection ~8 from the center of the base 26 to the reoote lateral periphery of about 0.~9 millimeters to about 0.90 millimeters (0.03 to 0.04 inches) lo is suitable.

The array of prongs 22 may be of any pattern ant density as desired to achieve the peel and shear strengths re~uired for the particular appl1cation of the fastening system 20. Generally as the array density increases peel strength and shear strength proportionately increase in a linear fashion. ~he ind1vidu~1 prongs 22 should not be so closely spaced as to interfere with and prevent the engaging means 30 of the adjacent pronqs 22 from intercepting strands or f1bers of the rece1ving surface. If the prongs 22 are too closely spaced compacting or ~tting of the receiving surface strands or fibers may occur occluding the openings between the strands or fibers. Conversely the prongs 22 should not be so distantly spaced as to require an excessive area of substrate 24 to provide a fastening system 20 of adequate shear S and peel strengths.
It is advantageous to dispose the prongs 22 in rows so that each prong 22 is generally equa11y spaced from the adjacent prong 22. The rows are generally oriented in the machine direction and cross-mach1ne direction according to the manufacturing process described and claimed below. Generally each machine direction and cross-machine direction ro~ of prongs 22 should be equally spaced from ehe adjacent machine direct10n and cross-machine direction ro~s of prongs 22 to provide a gener-lly uniform stress field throughout the fastening system 20 and the receiving surface when separat10n forces are applied to the fastening system 20 and the receiving surface.

As used herein the term ~pitch~ refers to the d1stance measured etther in the machine d1rect10n or cross-machtne ,. ~ .

i .
., wo 92~10g57 ~ ~ 9 PCT~US91/09462 ciirect~on, between the centers of the footprints of the bases 26 of prongs 22 in adjacent rows. Typically a fasten1ng system 20 haY1ng an array of prongs 22 with a pitch ranging from about 1.02 millimeters to about 5.08 ~illimeters (0.04 to 0.20 inohes) in both directions is suitable, with a pitch of about 2.03 millimeters (0.08 inches~ being preferred. Adjacent cross-machine direction rows are preferably offset approximately one-half pitch in the cross-machine direction to double the distance in the j machine direction between the adjacent cross-machine direction o rows.

The prongs 22 may be thought of as disposed in a matrix on a one square centimeter grid having an array of prongs 22 with about 2 to about 20 rows of prongs 22 per centimeter (5 to 50 rows per I5 inch) in both the machine and cross-machine directions, preferablyabout 9 rows of prongs 22 per centimeter (23 ~ro~s per inch) in each directton. This grid will result in a fastening system 20 having about 4 to about 400 prongs per square centimeter (2~ to 2500 prongs per square inch) of substrate 24.
The fastening system 20 prongs 22 may be made of any thetmally sensitive material which is stable and shape retaining when solid, but not so britt1e that failure occurs when the fastening system 20 is subjected to separation forces. As used '5 herein, ~therma11y sensitive~ means a material which gradually changes from the solid state to the liquid state upon the application of heat. Failure is considered to have occu..~ when the prong 22 has fractured or can no longer sustain a reaction in the prese -e of and ~hen sub~ected to sep-ratlon forces.
P~felably the material has an elastic tensile modulus, measured accord1ng to AST~ Standard D-638, of about 24,600,000 to about 31,600,000 kilograms per square meter (35,00 to 45,000 pounds per square inch~.

Further, the prong material should have a melting point 10w enough to provide for easy processing and a relatively high v1scos1ty to ptovide a tacky and tough consistency at te~pe~tu,es near the matetial melting point, so that the shanks 28 may be stretched and the engaging means 30 easily for~ed accotding to the method of ~ - rac~.e recited below. It is also imDortant that , . ~ .

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, - Wo 92lI0957 2 ~ 9 7 7 2 7 PCTJUS91109462 the prongs 22 be v~scoelast~c to allo~ for ~ore v~rt~t10n ln the parameters affect1ng prong 22 structure. and part1cularly the geometry of the engaging means 30. ~ater1a1 h-ving a complex viscosity ranging from about 20 to about I00 Pascal seconds at the temperature of application to the substrate 2~ is suttable.

The viscosity may be measured with a Rheometrtcs Model 800 Mechanical Spectrometer using the dynamic operating moJe at a I0 Hertz sampling frequency and IOX material strain. A disk and Io plate type geometry is preferred particularly with a d1sk having a radius of about 12.5 millimeters- and a gap of about I.0 millimeters between the disk and plate.

The prongs 22 are p~efe~entiallY comprtsed of a thermoplastic 1~ materia1. The term ~thermoplast1c~ refers to uncrosslinked polymers of a thermally sensitive ~aterial whtch flows under the application of heat or pressure. Hot melt adhesive thermoplastics are particularly well suited to manufacture the fastening system 20 of the present inventton p~rt1cularly in acco ~- ~e wlth the process described and clai0ed below. As used herein the phrase ~hot melt adhestve~ refers to thermoplastic compounds normally solid at roo0 temperature which become fluid at elevated temperatures and ~hich are applted in the molten state. Examples of hot melt adhesives may be found in the ~Handbook Of Adhesives Second Edition by Irving Skeist. published in 1977 by Van Nostrand Reinhold ComDany 135 ~est 50th Street New York He~ York 10020 which is incJ~po~ated herein ty (efe~ence. Polyester and polra~ide hot melt adhesives are particularly suitable and p~.r~.r~d. As used herein the terms ~polyester~ ~nd ~polyamide~
mean chains having repeating ester and amide units respect1vely.
If a polyester hot melt adhesive is selected an adhesive having a complex viscosity of about 23 + 2 Pascal seconds at about I94-C has been found to work well. ~f a polyamide hot melt adhesive is selected an adhesive having a complex viscosity of about 90 + I0 Pascal sec~nds at about 204-C has been found to work well. A polyester hot melt adhesive marketed br the Bost~k Company of M1ddleton Mass~ tts as Ho. 7199 has been found to work we71. A polya~ide hot melt adhesive marketed by the Henkel :, ' 092/10g57 ~9~ PCT/US9t/09462 Co~oanr of K~ e Illlno1s under the tr~den~ue ~-cro~elt 6300 has been found to work well.

In a second embodiment of the fastentng system 20 illustrated by Figure 3 the engaging means 30 may be generally semispherically (mushroom) shaped. ~he term ~semispherical~ means a generally round shape protruding in multiple directions and is inclusive of hemispheres and spheres but not liwtted to regular shapes. This geometry particularly the generally spherically o shaped engaging means 30 st.~c~ e provides the advantage that less disturbance to the strands of the receiving surface typically occurs when the engaging means 30 is remaved fro~ the receiving surface. This causes less visible damage to the receiving surface al10~ing it to be reused a greater nu ber of times. If the senispherically shaped engaging means 30 is selected the shank 28 is prefer-bly more nearly orthDg~n-l to the plane of the substrate 24 to allow easier pe etr~tion into the openings of the receiving surface and to reduce dam-ge to the receiving surface as the engaging means 30 is rele-sed from the receiving surface. A shank 28 having an angle ~ of about ~0- to about 90 is suitable.

To provide a prong 22 of the proper proport10ns and having a generall~ semispherical engaging means 30 the engagtng means 30 should rad1ally plotrJde from the circumrel nce of the shank 28 a lateral distance suff~cient to intercept the strands of the receiving surface~ but not pro~r de so far that the mass of the eng~ging means lO is unable to be rigidly supported by the shank 28 or the shank 28 is otherwise unstable. As the angle ~ of the shank 28 decreases i.e. dev1ates further from the pcl~nd1cular the mass of the engaging means 30 relative to the shank 28' s~r_ctu~al integrity and cross sectional area bec -~
more critical.

A tapered shank 28 having the base 26 to highest elevation aross sectional area and diameter ratlos descrtbed above and an angle o of the shank 28 o~ about 80- works well. It ls to be recognized the highest e~evat~on measurements ar~ to be taken from the highest elevation of the shank 28 and not from the eng~ging ~ ans 30 .
IT~ SHEET

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' 2~7727 Wo 92/10957 Pcr/US91~o9462 2~
For an embo~diment as tllustrated in F19ure 3 which does not h~ve a smooth trans1tion from the shank 28 to the engaging means 30 and for which the de0arcation bet~een the shank 28 and engaging means 30 is easily determined the imaginarr cutting plane 40 -40 is three-fourths of the per~endicular distance from the plane of the substrate 24 to the plane tangent to the point of the engaging means ~0 which is longitudinally closest to the plane of the substrate 24 . The cutting plane 40 -40 is then used to detenmine the angle ~ of the shank 28 the leading edge angle ~L and trailing edge angle ~T as described above.

The engaging means 30 should radi911y project in each lateral direction from the periphery of the distal end 29 of the shank 28 at least about 2S perceAe of the diameter of the distal end 29 of the shank 23 and preferably at least about 38 percent of such diameter. Alternat1vely stated if the diameter of the distal end 29 of shank 28 is nonmalized to l.0 the diameter of the engaging means 30 should be aS least l.S and preferably at least 1.75 times the dia~eter of the distal end 2g of the shank 28 . Furthermore the diameter of the base 26 should be about 2.0 times the diameter of the distal end 29 of the shank 28 .
The shank 28 height should be about 1.5 to about 2 times the diameter of the distal end 29 of the shank 28 to properly longitudinally space the engaging means 30 from the substrate ~5 24 . The long1tudinat dimension of the engaging means ~0 may range from about 0.5 to about 1.5 times the diameter of the distal end 29 of the shank 28 .

The fastening system Z0 of Figure 3 is made by heating the engaging means 30 and distal end of the fàstening system 20 of figure 2 to at least the melting point. Th1s is accomplished by bringing the engaging means 30 and distal ends of the prongs Z2 to a heat source longitudinall~ directed toward the plane of the substrate so that the base 26 and the proximal end of the shank 28 are not heated to at least the melting point. A suitable method is to bring the highest elevation of the prong to within about 3.3 miltimeters to about 10.1 millimeters (0.1 to 0.4 inches) of a heat source such as a hot wire heated to about 440-C.

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W0 92/10957 ~I a ~ pcr/us9l/os462 rhe lead1ng edge an~le ~L and tratltng edge angle ~T Of the prong 22 ~111 bc sim11ar to that of the c~espordlng hook-shaDed t1ne style engaging means prong 22. from ~htch the semisDherically shaped engaging means style prong 22 was formed. This occurs because the angle ~ of the shank 28 and leadlng edge and trailing edge angles ~L and ~T do not substantta11y change as the engaging means 30 of Figure 2 is heated and melted to flow into the engaging means ~0 of Figure 3.

For the aforementtoned Milliken 970026 receivin~ surface the engaging means 30 of Figure 3 should p~efe~ably have a lateral and longitudtnal dtmension of about 0.029 millimeters to ab~ut 0.032 millimeters (.~01 inches) and be dtsposed on a shank 28 having a base 26 diameter of about 0.30 millimeter5 to about !S D.04S millimeters (.012 to .002 inches) and a diameter at the distal end 29 of about 0.016 millimeters to aDout 0.020 millimeters (0.0006 to 0.0007 inches). The dtstal end 29 of the shank 28 should be disposed between about 0.44 millimeters and about 0.50 miltimeters (.017 inches to .020 inches) above the plane of the substrate 24 and the enga~ing means 30 should have a lateral project10n 38 of about 0.56 millimeters to about 0.70 mt11imeters (0.022 to 0.028 inches) p~eferably about 0.64 millimeters ~0.025 inches).

PROCESS OF MANUFACtUR~

The fastening system 20 according to the present invention may be mll~f~c h~ed using a modified gta~ur~ prtnting process.
6ravure prtnt1ng is well known in the art as illustrated by U.S.
~atent No. 4 643 130 issued February 17 1988 to Sheath et al.
and in~ o~ted herein by ~efere~e to illusSr~te the general state of the art. Referring to figure 4 the substrate 24 is passed through the n1p 70 formed be~l ~n two rolls a print roll 3S 72 and a baektng roll 74. The rolls 72 and 74 have substantially mutually parallel centerl1nes dtsposed generally parallel to the plane of the substrate 24. The rolls 72 and 74 are rotated about the respe~1ve centerlines and have generally equal surface velocittes in both magnttude and direct10n. at the ntp point 70.
If desired both the prtnt roll 72 and the backtng roll 74 ma~ be .
. , ~ . ' .
, : . . - .
,, ;, -W092, 2097727 0957 PCTtUS91/09462 dr1ven by an external mot1v- force (not sho~n) or one roll dri~en by external mottve force and the second roll drtven by frlction~1 ~rg~ rt with the first roll. An alternattng current electric ~otor h~ving an output of about 1.500 watts provides adequ~te motive force. By rotat1ng the ro11s 72 and 74 actuate a depositing means for depostt1ng the prongs 22 onto the substrate 2~.

The depositing means should be able to accommod~te the temperature of the material of pron~s 22 in the liquid state provide substantially uniforJ pttch b~ nr the prongs 22 in both the machine and cross-machine dtrect10ns and rteld the desired density of prongs 22 with1n the array. Also the depositlng me~ns should be able to ploiL~e prongs having various dlameters of the lS base 26 and heights of the shank 23. The print roll 72 specifically provides for the depostt1ng means to deposit the prongs 22 on the substrate 24 in the desired array dtscussed above (or other pattern) accord1ng to the p~esel\t manufacturing process. The phrase ~depostt1ng means~ refers to anything whtch transfers liquid prong material from a bulk quant1ty to the substrate 24 in dosa3es cc.. 5~0rdlng to lndtvidual prongs 22.
The term ~depos1t~ means to tr-nsfer prong mater1al from the bulk form and dose such matertal onto the substrate 2~ in units co~nlL cQndinq to ind1vidual prongs 22.
~5 One su1tahle deposittng means for depostt1nq prong material onto the suLstrate 24 is an ~rra~ of one or more cells 76 in the prtnt roll 72. As used herein the term ~cell~ refers to any cavtt~ or other component of the prtnt roll 72 wh1ch transfers prong material from a source to the substr~te 24 and deposits this mater1al onto the substrate 2~ 1n d1screte unlts.

The cross secttonal area of the cell 76 taken at the surface of the prlnt roll 72 generall~ corres~nds wtth the shape of the footprtnt of the base 26 of the prong 22. The cross sect10n of the cell 76 should be approxtmately equal to the destred cross sectton of the base 26. The depth of the cell 76 in part determines the longltudlnal length of the prong 22 speciflcall~
the pe~r~1cular dlst~nce fro the base 26 to the point or segment of h1ghest elevat10n. H~ L~e., as the depth of the cell :.. . , ,,,, ., , ~
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wc~ g2/logS7 ? ~ 9~ PCI~/US91~09462 76 increases to more than approximately 70 percent of the diameter of the cell 7~ the longitudtnal dimens10n of the prong 22 gener-lly re~ains constant. This 1s bec~use not all of the liquid prong material is pulled out of the cell 76 ~nd deposited on the S substrate 24. Due to the surface tension and viscosity of the 1iquid prong material. some of it ~ill rem~in in the cell 76 and not be transferred to the substrate 24.

For the e~bodiment described herein a blind generally o ~ylindrically shaped cell 76 having a dePth between about 50 and about 70 percent of the diameter is adequate. If desired the cell 7~ may be some~hat fru~troconically taDered in shape to accommodate conventional manufacturing processes such as chemical etching.
If frustroconically sh-ped the included angle of the taper of the cell 76 should be no more than about 45- to produce the pref~r.ed taper of th- sh~nk 28 and ~ield the base to highest elevation ratios discussed above. If the taper of the cell 76 has a greater included angle a prong 22 having too much taper result. If the included angle is too sm~ll or the cell 76 is c~ltndrical a shank 28 of generally unifor~ cross sect10n m~y result and thereby have areas of higher stress. For the embodiment described herein a cell 76 having an included angle of about 45- a diameter at the roll periphery of about 0.89 millimeters to about 1.22 millimeters (0.035 to 0.048 inches) and a depth ranging fro- about 0.25 millimeters to about 0.51 millimeters) O.~l to 0.02 inches p~oduces a suitable prong 22.

~he print roll 72 and backing roll 74 should be compressed coincident with the line e~rl~et1ng the centerlines of the rolls to press the adhesive from the cells 76 in the print roll 72 onto the substrate 24 and to provide sufficient fricttonal 2nga5~ ent to drive the opposing roll if it is not externally driven. ~he backtng roll 74 should be somewhat softer and more compliant than the print roll 72 to provide cushioninq of the prong material as it is deposited on the substrate 24 fro~ the pr1nt roll 72. A
back1ng roll 74 having a rubber coat1ng ~tth a Shore A durometer hardness of about ~0 to about 60 is suitable. The rolls ~2 and ~l mar be pressed t~ ~r ~ith such a force that an i~pression in . : , . . ~
, . ~

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WO 92~10957 2 ~ 9 7 7 2 7 P ~tUS91/09462 the machine direct10n of about 6.4 milltmeters to about 12.7 mtllimèters (0.25 to ~.50 inches) is obtatned. As used heretn the term ~impresston~ refers to the contact are~ of the softer roll on the substrate 24 as it passes through the nip 70.

The print roll 72 is p.ef~ably heated to prevent solidification of the prongs 22 during transfer from the source through the deposition on the substrate 2~. Generally a print roll 72 surface temperature near the source material temperature is desired. A print roll 72 te~peratùre of about 197-C has been found to work well with the polyester hot melt adhesive marketed by the Bostik Comoan~ of Middleton Massachusetts as No. 7Ig9.

It is to be recognized that a chilt roll may be necessary if the substrate 24 is adversely affected by the heat transferred from the prong material. If a chill roll is desired it ~y be incor~orated into the bac~ing rol1 74 us~nq means well kno~n to one skilled in the art. This arrangement is often necess~ry if a polypropylene polyethylene or other polyolefinic substrate 24 is used.

The material used to forw the individual prongs 22 ~ust be kept in a source which provides for the proper temperature to apply the prongs 22 to the substrate 2q. Typically a temper~ture ~5 slightly above the me~ting point of the material is destred. The material is considered to be at or above the ~melttng point if the material is parttallr or wholly in the 7iquid state. If the source of the prong m~terial is kept at too high a temperature the prong material may not be viscous enough and may produce en~qing means 30 which laterally connect to the prongs 22 adjacent in the machine dtrectton~ If the material tempe~tu.~ is ~ery hot the prong 22 will flow into a small some~hat semtspherically shaped puddle ànd an engagtng mé-ns 30 will not be formed. Conve(sely if the source tempe~atute is too lo~ the prong material may not transfer from the source to the means for deposittng the material or subse~ tly may not properly transfer from the depositing means ~6 to the substrate 2~ in the desired array or pattern. The source of the material should also imoart a generally untform cross-machine dtr-ctton te oer-ture ~0 profiie to the matertal be-in com~un1cat10n ~1th the ~eans for :,, .. : '~ , ~ i.

wo 92/10957 ~ ~ 3~ ~ ~ i PCr/Uss1/os462 depositing the ~dhestve m~ter1al onto the substr~te 2~ ~nd easily be replenished or restoc~ed as the prong m~teri~l becomes depleted.

A suitable source is a trough 80 substantially coextensive of that portton of the cross-machine dimension of the print roll ~2 which has ce11s 76 and adjacent thereto- The trough 80 has a closed end bottom an outboard side and ends. The top may be open or closed as desired. The inboard side of the trough 80 is open allowing the liquid material therein to freely contact and communicate with the circumference of the print roll 72.

The source i5 externally heated by kno~n means (not shown) to maintain the Drong material in a liquid state and at the proper temperature. The prefe.. ed temperature is above the melting point but below that at which a significant loss of viscoelasticity occurs. If desired the liquid matérial inside the trough 80 may be mixed or recirculated to promote homogeneity and an even temperature distr1bution.
Juxtaposed ~ith the bottom of the trough 80 is a doctor blade 82 which controls the amount of prong material applied to the print roll 72. The doctor blade 82 and trough 80 are held station-ry as the prtnt roll 7Z is rotated allowing the doctor ~5 blade 82 to ~ipe the circumfelence of the roll 72 and scrape any prong material ~h1ch is not disposed with1n the individu~l cells 76 from the roll 72 and allows such material to be recycled. This arrangement allows prong material to be deposited fro~ the cells 76 to the substrate 2~ in the destred array according to the geometry of the cells 76 on the circumfelente of the print roll 72. As seen in Figure 4 the doctor blade 82 is p~eferentially disposed in the horizontal pl~ne part1cu~arly the horizontal apex of the prtnt roll 72 which apex is upstream of the nip point 70 After being deposited onto the substrate 2~ the prongs 22 are severed from the print roll 72 and the deposit1ng means 76 by a severing means for severing 78 the prongs 22 into the engaging means 30 of the fastening system 20 and a mo11. As used herein the term ~moil- refers to any material se~e~ed from the orong 22 and which do~s not form part of the fastening syster 20.

wo 92/10957 2 ~ 9 ~ 7 2 7 PcT/US91/n9462 The severing means 78 snould be ~dJust~ble to acco~odate various slzes of prongs 22 and lateral projecttons 38 of engaging means 30 and also provide un1form1ty th o ~t the cross-machine direction of the array The term ~sever1n9 means~ refers to anything which longitudinally seParates the moil from the fastening system 22 The term ~sever~ refers to the act of dividing the moil from the fasteninq system 20 as described above The severing means 78 should also be clean and should not rust oxidize or impart cu ~dents and contaminates (such as moil o material) to the prongs 22 A suitable severing means is a wire 78 disposed generally parallel to the axis of the rolls 72 and 74 and spaced from the substrate 2~ a dtstance which is somewhat greater than the pe per~icular distance from the highest elevation of the solidified prong 22 to the substrate 24 i5 P~efc~ably the wire 78 is electrically heated to prevent build-up of the molten prong material on the severing means 78 accommodate any cooling of the prongs 22 which occurs between the t1me the prong materia~ leavés the heated source and severing occurs and to promote lateral stretching of the eng-ging means 30 The heating of the severing me-ns 78 should also provide for unifonm temperature d1str1but10n in the cross-mach1ne direct10n so that an array of prongs 22 having subst~nt1ally uniform geometry is produced ~s Generally as the prong matertal te~perature increases a relatively cooler hot wire 78 te0pe -t~ e severing means can be accommodated Also as the speed of the substrate 24 is decreased less frequent cooling of the hot wire 78 occurs as each prong 22 and moil are severed m-king a relat1vely lower wattage hot wire 78 more feasible at the same temperatures It should be recognized that as the tempL~tulc of the hot wire 78 is increased a prong 22 having a generally shorter sh-nk 28 1ength will result Con~elsely the shank 28 length and l-ter-l length of the engaging means 30 will be increased in inverse proport10n as the temp~r~t~ e of the hot wire 78 is decreased It is not ne~sary that the severing means 78 actually cont~ct the prong 22 for severing to occur The prong 22 m-y be severed by the radiant heat eattted from the severing means 78.

S U ~ ~ lll ~ T E S ~ E E T

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wo 92/10957 ~ ~ 9 ~ pcT~us91/o9462 3o For the e~bodtment described heretn a round cross sect10n n1c~el-chromtum wire 78 h~v1ng a diamreter of abaut 0.51 m111imeters (0.02 inches) heated to a temDer-tu~e of about ~43-C
to about 4I6-C has been found suttable. It will be aDparent that a knife laser cutttng or other sevêring means ~8 may be substituted for the hot wire 78 described a~ove.

It is important that the severing means ~8 be disposed at a positton which allo~s stretching of the prong material to occur o prior to the prong 22 being severed fro~ the moil. If the severing means 78 is disposed too far from the plane of the substrate 24 the prong material will pass underneath the severing ~e~ns 78 and not be intercepted by it ~orming a very long engagtng means 30 whtch will not be prorêr1y spaced from the !5 substrate 24 or adjacent prongs 22. Converse1y if the severing means 78 is disposed too close to the plane of the substrate 2~
the severing means 78 will truncate the sh-nk 28 and an engaging means 30 may not be formed.

A hot wire severing means 78 dtsposed approximate1y 14 m111tmeters to 22 milllmeters (0.56 to 0.88 inches) preferdbly about 18 millimeters ~0.72 lnches) in the machtne directton from the nip polnt 70 approximately 4.a millimeters to 7.9 millimeters (O.I9 to 0.3I inches) preferably aDout 6.4 millimeters (0.25 '5 inches) radially outward from the bac~ing roll 74 and approximately 1.5 millimeters to approximately 4.8 millimeters (0.06 to O.I9 inches) plefe-ably about 3.3 millimeters (0.13 inches) rad1ally outwardly from the print roll 7Z is adequately pos1tioned for the process of man~ractu-e disclosed herein.
In operatton the s~bstrate 24 is ttan~pG~ ted in a first dtrect10n relative to the depostt1ng means ~. More particu1arly the substrate 24 is trar.spG.~ed through the nip 70 prererentially dra~n by a take-up roll (not shown~. Thts provides a cle2n area of substrate 24 for cont1nuous depos1t10n of prongs 22 and removes the porttons of the substrate 24 having prongs 22 deposited thereon. The dtrectton generally parallel to the principal d1rectton of transport of the s~bstrate 24 as 1t passes through the nip 70 ts refe..ed to as the ~machine directton.~ The machine directton as ind1cated by the arrow 75 of F1gure 4 is generall~

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f wo g2/l09s7 2 0 9 7 7 ~ 7 PCT/US91/09462 orthogonal the centerltne of the prtnt roll 72 and bac~ing roll 7~. The direction generaliy orthogonal to the machtne direction and parallel to the plane of the substrate 2~ is ref~. ~d to as the ~cross-machine direction.
The substrate 24 may be dra~n through the nip 70 at a speed approximately 2% to approximately lOX greater than the surface speed of the rolls 72 and 74. This is done to minimi2e bunching or puckering of the substrate 24 near the means for severing 78 the prongs 22 from the means for depositing the prong material on the substrate 24. The substrate 24 is trans~cr~ed throuqh the nip 70 in the first direction at about 3 to about 31 meters per minute ~10 to 100 feet per minute).

!S The angle of the shank 28 can be influenced by the rate of transport of the substrate 24 past the nip 70. lf prongs 22 having a shank angle ~ more nearly ~e.~ondicular to the substrate 24 is desired a slower rate of transpo.~ of the substrate 24 in the first dtrection is selected. Cor~ersely if the rate of transport is increased the angle ~ of the shank 28 decreases and an engaging means 30 have a greater lateral projection 38 will result.

If desired the substrate 24 ma~ be inclined at an angle ~
approximately 3S- to approximately 55- pr.fe~ably about 45- from the plane of the nip 70 to~ards the backtng roll 74 to utilize the viscoelast~c nature of the prong material and properly orient the engaging ~eans 30 in the lateral dtrection as well as longitud~na1 direction. This ar~ilg t also provides a greater force to extract the prong material from the cell 76 and to pull the prong 22 away from the print roll 72. The angle ~ from the plane of the nip 70 should be increased as a lesser angle ~ of the shank 28 is desired. Also increasing the angle ~ of deviation from the plane of the nip 70 has a ~eak but positive effect to produce engaging means 30 having a greater lateral projection 38.

After depostting prong material fro~ the celt 76 onto the substrate 24 the rolls 72 and 74 cont1nue rotatton in the tirections indtcated by the arro~s 75 of Figure 4. This results 40 in a period of relative displace ent b~t~ the transported S~J8sTJTuTE S~r~

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WO 92~10957 ~ ~ 9 ~ ~ 27 32 pcT~ussl/o9462 substrate 2~ and the cells 76 durtng whtch period (prior to severtng) the prong matert~l bridges the substrate 2~ and print roll 72. As relattve d1sp1ace~ent cont1nues the prong material is stretched unt11 severing occurs and the prong 22 separated ~m S the cell 76 of the print roll 72. As used herein the mm ~stretch~ means to increase in linear dimension at leas a portion of which increase becomes substantiatly permanent for the life of the fastening system 20.
o As discusse~ above. it is also necessary to sever the individual prongs 22 from the print roll 72 as part of the process which forms the engaging means 30. ~hen severed a prong 22 is longitudinally divided into two parts a distal end and engaging means 30 whtch remain with the fastening system 20 and a moil (not lj sho~n) which remains with the print roll 72 and may be recycled as desired. After the prongs 22 are ~evered from the moil the fastening system 20 is allowed to freeze prior to contact of the prongs 22 with other objects. After solidificat1On of the prongs 22 the substrate 24 may be wound into a roll for storage as desired.

A nonl1m1t1ng illustration of the process shows the prong materia1 to be dtsposed in the trough 80 and heated by means commonly known to one ski11ed in the art to a temperature s;~ ~t above the melt1ng point. If a polyester resin hot melt adhesive is selected a material temDerature of approximately 177-193-C prefe.a~ly about 186 C has been ~ound suitable. If a polya~ide resin is selected a material temperature of approxi~tely 193-213-C pre~e.~ ly about 200-C has been found suitable. A one side bleached kraft p~per substrate 24 about 0.008 to about 0.15 millimeters (0.003 to 0.006 inches~ in thickness works well with hot ~elt adhesive prongs 22. The pron?s 22 are joined to the bleached side of the kraft paper substra:e 24.
For the illustrated operation described herein print roll 12 ha~ing an array of about 5 cells 16 per centtmeter (13 cells 76 per inch) in both the mach1ne dtrect1On and cross-machine dtrecttons ~ielding a grid of about 26 cells 76 per square centtmeter (169 cells 76 per s4uare inch~is sutt~ble. Th1s grid i ,.. , . ~ . .
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WO 92/10957 PCTtUS9t/Os462 density may be advantageously used with a pr1nt roll 72 having ~
diaoeter of about 16 cant heters (6.3 tnches) ~ith cells 76 about 1 m111imeter (0.045 inches~ in diameter and about 0.8 millimeters (0.030 inches~ deep. A backing roll 74 having a diameter of about s lS.2 centimeters (6.0 inches) and vertically registered has been found to work well with the afor~ ~rtioned print rolt 72. The rate of transport of the substrate 24 is about 3.0 meters per minute (lO feet per minute).

A nickel-chromium hot wire 78 having a di~meter of about O.S
millimeters (0.02 inches) disposed approximately la millimeters (0.72 inches) from the nip point 70 in the machine direction approximate1y 0.3 milli~eters (0.13 inches) radially outwardly from the print roll 72 and approxim~tely 6.4 millimeters (0.25 inches) radially oui1ardly from the backing roll 74 is heated to a temperature of about 382-C. The fastening system 20 produced by this operation is subst~ntially similar to that illustrated b~
Figure 1 which fastening system 20 may be advantageously inco~po~ated into the illustrative article of use discussed below.

~ithout being bound by any parttcular theory it is believed that the geometr~ of the engaging means 30 is ;c~er..... ed by the elastic properties of the hot melt adhesive used to make the prong 22 and the differerce in the temperature te~w er the trailing edge 46 and the lead~ng edge 42 of the prong 22. The trailing edge 46 of the prong 22 is shielded and insulated from the heat 2S originating fro~ the severing means 78. Cor~erselr the leading edge 42 is d1rectly exposed to the heat of the severing means 78 which causes the lead1ng edge 42 to solldify or freete after the trailing edge 46. This causes elongat1On of the leading edge 42 and contraction of the trailing edge 46 relat1Ye to each other.
As thts temperature d~ffe.al~e is increased a relat1vely longer engaging means 30 is formed.

If desired a fastening system Z0 having relat1vely vér~
s~alt prongs 22 (not sho~n~ may be m~de by form1ng a natural pattern from the pr~nt roll 72. As used herein the term ~natural 3S pattern~ refers to array of prongs 22 result1ng from a pr1nt roll72 which does not have cells 76 d1sposed t~e ~r but instead which ut11izes the surface of the roll 72~as She depos1t1ng means ~ - . . . ,,, . . : : ..
, . . . . .

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W0 92llO95~ 37~ 2~ 34 P~/US91/09462 ~6 Thus the p~ttern of prongs 22 is formed by the clear~nce be; aen the doctor bl~de 82 and the prtnt roll 72 and to a lesser extent by the surface fin1sh of the print roll 72 The doctor blade 82 should be adjusted to provide about a gap of about 0 03 millimeters to about 0 08 millimeters ~0 001 to 0 003 inches) in radial clearance from the print roll 72 To form a natura1 pattern the ver~ sm~ll sized Drongs 22 resultin~ fro~
such a print roll 72 are advantageously utilized with a o rettculated foam receiving surface that does not have strànds and openings there~2~u- e but rather incurs localized elastic defo ttons whtch resist separation of the fastening system 20 Referrtng to Figure S if a fastening system 20 of more near~y isotropic peel strength is desired such a fastening system may be fonmed by mod1fying the fastening system 20 of Figure 1 through a second stage dtfferent1al temperature process As illustrated in Figure 5 the f~stening system 20 of Figure I is further processed to provtde shanks 28 with engaging means 30 which radially extend from the shanks 28 in v~rious lat~ral dtrect10ns of a generally random or1entat10n The phrase ~random orientat10n~ ~e~ns having lateral projecttons 38 and profile views whtch signiftcantly dev1ate in direction from those of the nearby prongs Z2 ~ 1thout being bound by any particular theory it is believed th~t this stn. ~ e is accomplished by establishing a temperature d1fferent1al between the proflle su\faces or leading surfaces ~2 and the trailing sulr~es 46 of the prongs 22 of the fastening system 20 of Figure 1 and th~t such tempe~eat~ e d1fferential may be er ~ced by radi~t10n or prefefably conve tlon It is also belteved that as a result of attaining a temperature differential of the leading surface 42 or the profiîe s~(fa es relative to the trailing surface 46 the engaging means 30 will substant1all~ change or even reverse the orientat10n of later~l projection 38 provid1ng a prong 22 which is or1ented in a direct10n other than that which occ~ ed when tn1t1all~ cooled or frozen The d1ffe~ent1~1 te0per~ture m-~
be est~bl1shed b~ an~ source known to one sk111ed 1n the art such T ~ ~J ~ - T

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f WO 92l10957 2 0 ~ 7 7 2 7 P ~/US91/09462 as a heated ~irc or metal element and ~refe~bly an ~ir gun 84 dtsposed aoove the prongs 22 and capable of provid1ng a directed te~perature d1fferent1al ~o the fastening s~stem 20 .

It is desired that the dlrected temperature dtfferential source direct an air current towards the fastening system 20 within about + 90- of the first direction of substrate 24 travel which is the machine direction. As used herein the phrase ~+ 90- of the first direct10n~ means a direction having a vector c~relt generally pe.~e~dicular to or generally counter to the first direct10n of travel of the substrate 2~ and is inclusive of the direction generally opposite the first direction of travel.
lf the d1rected temperature dlfferential source 84 is disposed at an angle of about 180- relattve to the ftrst direct10n of travel of the substrate 24 the source 84 is directed towards the leading surfaces 42 of the prongs 22 of the fastening system 20 and generally opposite the machtne directton of the process described and clatmed herein. Olrect1ng the tem4erature d1fferent1al of source 84 d1rectly to~rds the lead1nq surface 42 of a prong 22 will result in the lateral projectton 38 of the engaging ~eans 30 rotating to change the orientation of the lateral projection about I80 . Prongs 22 dtsDosed some~hat to the side i.e. in the cross-machine direct10n of the directed temoeratu~ d1fferent1al source 84 will not have the engaging means 30 rot~ted about 180- but instead engaging means 30 ~ore nearly rotated about 90-. Thus it is apparent that a d1rected tesp~t~.e dtffe~ent1al source 84 or1ented in the cross-mach1ne dtrection will provide a fastening system 20 having prongs 22 with vartous lateral ortentations in the cross-~achine ttrectton accord1ng to the prong 22 position relattve to the temp at~ d1fferent1al source 84.
3S An air gun 84 discharging air at a te0perature of about 88-C
at a distance of about 46 cent1meters (18 inches) from the substrate 24 is a suit~ble dtfferenttal temperature source. A
133-348 series heat gun sold by the Dayton Electr1c Manufacturtng Compan~ of Chicago Illinois oriented at about 45- rel~t1ve to the pl~ne of the substrate 24 and dtsposed about 46 centt~eters (18 ~,' ~ - , .

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~O 92/10957 ~ ~ 9~ PCTtUS91/09462 1 inches) fro~ the prongs prod~re~ a f~stening system 20 pattern subst-nttally stm11~r to that shown in Figure 5. It will be apparent to one sk111ed tn the art that a one or ~ore hot wires disposed above the pronqs 22 and oriented in the machine direction will produce a fastening system 20 h~ving cross machine directionally oriented engaging means 30 in a regular somewhat striped pattern.
~ithout being bound by any theory it is believed that the o change in orientation of the engaging means 30 occurs due to the cooltng of the profi1e surfaces or the leadtng surface 42 of the prong 22 relative to the trailing surface ~6 which may occur if the temperature of the discharged air fro0 the directed temperature source d1fferential source 84 is less than the temperature of the periphery of such profile surfaces or leading surface 42 . The temperature different1al result1ng from the cooling causes contractton of the portton of the prong 22 towards which the temperature diffe~e..~ial source a~ 1s directed.
Thts contract10n m~y result in a chanqe in the orientation of the engaging means 30 and lateral projectton 38 due to the dtfferential cooling of the lead1ng surface 42 relative to the trailing surface ~6 . ~tthout being bound by further theory it is believed that rel1ef of residual stresses which occur during cooling m-y influence the change in orientation of the lateral 2S projection 38 .
It ~ill be further to apparent to one skilled in the art that other variat10ns are feasible. For examole a prong 22 having an engaging means 30 protruding in more than one dtrect10n may be formed or free fonmed prongs 22 may be p.. h-:ed by commanly known methods other than g-a~.e printing. If desired only one roll may be uttlized in the manufacturing process providtng the substrate 2~ contacts at least about 180- of the peripher~ of such roll.
It is f~ca~ ?rtly desirable to have a fastening system 20 of the present invent10n wtth the maximum lateral projectton 38 of the prongs 22 ortented in a direction other than the machine dtrect10n. For exa~ple when using the present invent10n as the fastening ~eans of a dtsposable d1aper it is desirable that the ' , . . ~

w~ s2/to957 2 Q ~ 7 7 2 7 PcS/USsl/09462 ~axi~u~ lateral proiect1on 38 of the prongs 22 be or1ented tn a d1rection substanttally pel~e~d1cular to the d1rect10n of travel of the dtsposable d1aper on the manuf~cturinq ltne. A d1aper manufacturing line requtres complex and expensive machinery to cut reorient and apply the fastening syste~ 20 if the maximum lateral projection 38 of the prongs 22 are oriented in the machine direction. A fastening system 20 of the present invention produc~d with the maximu~ lateral projectton 38 of the prongs 22 oriented in the cross-machine direction however would not require re-orientation before being applied to a disposable d1aper. It is therefore very advantageous to be ab1e to manufacture the fastening system 20 of the present inventton with the maximum lateral projectton 38 of the prongs 22 oriented in a dtrection other than the ~achtne d1rection.
There are two ansles which are 0ade by the shank 28 of prongs 22 p~oJuced by thts process. The shank 28 0akes an angle a with the plane of the substrate 24 as discussed hereinbefore and the sh~nk 28 also makes an azi~uthal angle (indicated by a letter A
Fig. 7) relative to the m-chine directton of the substrate 24. As used herein the term ~azimuthal angle~ refers to the angle the maximum lateral project10n 38 m kes re1~t1ve to the ~achine directton of the substrate when viewed from above. As used herein ~viewed from above~ refers to viewing the prongs 22 from a dtrection whtch is per~r~1cular to the plane of the substrate 24.
The tenm ~machtne directton~ refers to the direction generally parallel to the princtple dtrection of trarsp~t of the substrate 24 as it passes through the nip 70 and is indicated by an arrow in Figure 7. The azimuthal angle is ~easured by first determininq the maximum lateral projectton 38 of the prong 22 as disclosed hereirbefore. As shown in Figure 7 the aztmuthal angle ind1cted by the letter A is the angle relattve to the a~chine directton wh1ch is m~de b~ a line 60 drawn p-r-llel to the a~ximu~
lateral projection 38 when viewed fro~ above. The azimuthal angle A can be ~easured relative to the machine directton in either the clockwise or counter-clockwise direct10n. but the aztmuthal angle will not be greater than 180 . A fastening s~ste~ 20 suitable for use on a disposable diaper will p~efe~bly h-ve prongs 22 with an aztmuthal angle such that the m ximu~ later 1 pro~ection 38 will 40 be ortented in a direct10n having a vector coaponent P~-r rdicular W092/109S7 ~,~9~ rl PCI~/US91/094~2 1 to the machine d1rection of the substrate 24. Thus the prongs 22 may have an azimuthal angle greater than 0 degrees between about l degrees and about 180 degrees generally the aztmuthal angle ~ilt bè greater than about 20 degrees (20- - 180-) greater than about 45 degrees (45- - 180-) or greater than 60 degrees (60- -180-). The azimuthal angle of the prongs 22 ~ade using the process described herein wtll prtfe~ably be from about 20 degrees to about 160 degrees more preferably from about 45 degrees to aoout 135 degrees and most preferably from about 60 degrees to o about 120 degrees. In a prefe. ed embodiment shown in Figure 7 the azimuthal angle of the prongs 22 ~ill be about 90 degrees.

A method for impart1ng an azimuthal angle to the fastening system 20 is to bias the prongs 22 of the fasten1ng system 20 lS while the prongs 22 are partially or wholly in a liquid state. As used herein the term ~btas~ refers to providing a force or influenctng means in a d1rect10n having a vector component pe ~endicular to the machine d1rectton of the substrate 24. The pronqs 22 may be btased when they are newly formed and have not yet cooled and solidif1ed and are st111 maleable or the prongs 22 may be biased after they have cooled and solidified by reheating the prongs 22 so that they are maleable and will turn when biased.
There are a number of methods available to bias the prongs 22 so as to impart an azimuthal angle.
A suitable method for impartSng an azimuthal angle is to bias the prongs 22 by causing gravitattona1 forces to act upon the prongs 22 while the prongs 22 are part1ally or wholly in a liquid state such that the gravttational forces will pull the prongs 22 to the des1red aztmuthal angle. Thts can be accomplished by t11ting the substrate 24 so that the plane of the substrate 24 when viewed in the mach1ne direct10n ~ould not cut p~.~erdicularly through a plum line but rather would form an angle other than 90 degrees with a plum line. As the prongs 22 are printed and severed the angle indicated by the letter H in figure 8 of the substrate 24 relative to the horizontal allows gravitat10nal forces to act upon the dtstal ends of the shanks 28 and engag1ng me-ns 30 and pull the prongs 22 toward the longltudtnal s1de of the ~ rate 2~ having the lo~er alt1tude.
F.ef~.ably the pr1nt roll 72 and the-bac~ing roll 74 together are ~ wo 92/1n957 2 ~ 9 7 7 2 7 PCTlUSgl/09462 ttlted or raised on one end from the hortzontal as shown in ftgure B so that as the substnte 24 passes through the n1p 70 of the rolls the longitudinal edges of the substr~te 24 ~ill be at n~ne~ ~l altitudes and the gr~vitattonal forces indlcated by the letter G in fiqure 8 will act upon the pronqs 22 to give the shank 2a an angle ~ with the substrate 24 and an azimuthal angle A
(neither angle Q or ang1e A ~re shown in figure 8). The substrate 24 should be ttlted so that the plane of the substrate 24 forms an angle relative to the horizontal of at least about 15 degrees.
o Preferably the plane of the substrate 24 will be at an angle of at least 30 tegrees.

In a nonlimiting example of the process one may use aost1k polyester hot melt adhesive J7199 heated to a temDerature of about 38~-F (197-C); a print roll 72 having cells 76 with a diameter of .040 inches (.102 centimeters) and a depth of .018 inches (.046 centimeters) heated to a te perature of about 350-f (177-C); a substrate of white kraft p~per having a basis we1ght of .08 milligrams per square meter travellng at a speed of 14 feet (4.266 meters3 per minutes; and the print roll 72 and a backing roll 74 will be inclined to an angle of about ~0- relative to the horizontal.

Another suitable method for impart1ng an azimutha1 angle is S to bias the prongs 22 by applying a pressure differential across the plane of the substrate 24 while the prongs 22 are part1ally or wholly in a liquid state such th-t the prongs are forced or drawn to the desired azimuthal angle. This may be accomplished by flowing a 1iquid or gas across the plane of the substrate 24 in a dirèction h~ving a vector co~ponent pe.~endtcular to the machine direction. The pressure different1al will cause the prongs 22 to turn or reortent toward the sidc of the sub trate having the lower pressure. Preferablr the p.ess~re dtffe\ent1al across the substrate 24 is achievet b~ creat1ng a high pressure fro~ one side of the substrate 24 using air jets air needles or other means well known in the art. However the pressure differentlal across the sub trate 24 may also be achieved by p~ ing a low pressure ~i.e. vacuum or part1al vacuum~ fro~ one side of the substrate 24 or by creating a high pressure fro~ one s1de of. the substrate 24 and at the sa~e tt~e creating a low pressure from the other .

~:, WO g2~10957 ~ PCT/US9t/09462 ~
side of the substrate 2~. T~e side of the substr~te 24 nh1ch ~epresents the h1gh pressure or low pressure s1de and the ang1e relative to the machine direct10n at wh1ch the nuid flows is ~eFerd-~t upon the azimuthal angle desired. ~he fluid medium used will preferably be air though other ~ases and liquids may also be used. As used herein the term ~high pressure~ refers to a pressure greater than the ambient pressure of the air or other fluid which s~. ~wnds the prongs 22 as they are be1ng azimuthatly angled. As used herein the term ~low pressure~ refers to a pressure less than the a~bient pressure of the air or other f1uid which su- ~- s the prongs 22 as they are betng azimuthally angled.

It should be unde~ ~ood that it would also be suitable to have the high pressure and/or lo~ pressure originating from other than the sides of the substrate 2~. That is the high pressure source and~or low pressure source ~ay be pos1t10ned such that the prongs 22 are forced and/or dra~n in more than one direct10n giving the fastening system 20 a ~ore isotrop~c peel strength. As a nonlimiting example a vacuum source may be d1sposed near the sides of the substrate 2~ and a pressure source d1sposed near the middle of the substrate 24 such that the maxi~um lateral projection 38 of the prongs 22 will be influenced substantially away from the middle of the substrate 24 and toward the sides of the substrate 24~

~hen a pressure different1al is used to impart an azimuthal angle to the prongs 22 rrt~ ~ tl~ turbutence in the chosen fluid medtum will c~use some of the prongs 22 to scatter or acquire an undesired azimuthal angle. To minimize the inctdence of prongs 22 scattering it is desirable to minimi2e the turbulent flow of the fluid medium and maintain a more streamline or laminar flow There are a number of methods available to prod~ce a su~stantially laminar flow.
One method of producing a substanttally l~minar flow is through the USQ of one or more nozzles or n ow ampl1flers to tmpart controlled dtrectton to a flow. As a non-ltmittng examP1e two co~erclal air flow a~pltfiers 902 will be used in tandem.
The ftrst air flow amplifter 902 (1ndtcated b~ the letter P in ~ w o 92/logs~ 2 ~ 9 7 7 2 7 PCTIUSgl/09462 Fiq. 9) has the dtscharge f~o~ of it5 outlet d1rected across the substrate 24. The second air flo~ a~pltfier 902 (ind1cated by the 1etter V in Fig. 9) has the suct10n of tts inlet dra~ing from across the substrate 24. The discharge flow of the first air flow amplifier P is drawn into the inlet of the second air flow amplifier V creattng a substantt~11y linear air draft. The air flow amplifiers 902 are oriented relattve to the substrate 24 to pr~ u~e a low veloc1ty linear air draft in a cross-machine dtrect10n. The prefe..ed locatton of the linear air draft is lo immediately down stream of the cutttng hot wire 78 (not shown in Figure 9). Extraneous atr current may be el1m1n~ted by the use of an enclosure (not shown) to s~r. -i the area where the linear air draft is applied. S~itable air flow ampltfiers are co~erc1ally available from Vortec Corporat10n of Cincinnat1 Ohio and marketed as Transvector Model 912/952 h-ving a 25-lOO SCFM rating~ ~he required air pressure may vary but about 1 ps1 to about lO psi of air pressure works well.

Another su1table method for iopart1ng an azimuthal angle to the prongs 22 is to b1as the prongs 22 by mechanically turning or physically draggtng the prongs 22 nh11e they are partlally or wholly in a 11qu1d state. A non-1io1t1ng example of th1s ls the use of an osc111at1ng or rotat1ng severing means e.g hot wire (not shown) to force or drag the prongs 22 to the desired azimuthal angle as the prongs 22 are cut. There will be many other methods of accompltshing th1s nhich will be apparent to one skilled 1n the art.

It should also be understood that an azimuthal angle ma~ be i~parted to the prongs 22 by ustng a comb1nat10n of methods to bias the prongs 22. A nonl1mtttng example of the use of combtnat10ns of methods is the use of grav1tat10nal force and a pressure dtfferent1al across the plane of the substrate 24 in combinat10n to impart an az1muthal angle to the prongs Z2.
Ar~t~en non-11mit1ng example is the use of gravttat10nal forces and a rotat1ng sever1ng means in comb1nat10n to iopart an aztmuthal ang1e to the prongs 22. M-ny other methods of impart1ng an aztmuthal angle to the prongs 22 ~ill be apparent to one sk111ed tn the art as ~ill the various co~b1nat10ns of methods.

' W092~10957 ~9~2 t PCT/US91/09462 ~
ILLUST MTrVE ARTICLF OF USE

An illustrative and nonli~tttng ex-m~le of the usage of the fastening system l20 of the present invention in an artlcle cf ; manufacture follows and is illustrated in Figure 6. Mechanical fastening syste~s have been advantageouslY used in disposable absorbent articles as disclosed in U.S. Patent Application Serial No. 07/132.281 Issue Batch No. H97 filed on ~ecember 18 1987 in the name of Scripps which application is incG vcrated herein lo by reference for the purpose of showing a diaper 110 structure and the advantageous utilizat10n of mechanicat fastening systems 20 in such diaPer 120 structures.

It is known for example that mechanical fastening systems Is 120 are less easily contaminated by oils and powders than are adhesive tape fastening systems and further may be easily reused. All of these features provide advantages whcn applied to a disposable diaper 110 intended for use on an tnfant. Also a refastenable fastening system provtdes the advantage that the infant may be che:.~d to see if sotling of the dtsposable diaper llO has occu.red turing the we~ring period.

Referring to figure 6 there is shown a disposable diaper IlO
intended to be worn about the lower torso by an infant. As used ~5 herein the term ~disposable abso.bent arttcle~ refers to a garment generally worn by infants or incontinent persons and which is drawn between the legs fastened about the w~ist of the wearer and intended to be discarded after a singte use and not to be l~ -dered or restored. A ~disposable diaper~ is a particular dtspos~ble artlcle intended and scaled to be worn b~ ~n infant.

A prtfer~ ~ diaper 110 co0prises a liquid pervious topsheet 112 a liquid impervious bac- heet 116 and an absorbent core 118 intermediate the topsheet lI2 and bac~sheet 116. The tops~eet 112 and b~c~cheet 116 are at least partlally pertpherally joined to ensure the core 118 is held in pcsitlon. The dtaper 110 elements may be assembled in a variety of conftqurat10ns well ~nown to one skilled in the art wtth a plefel.ed configuratton being generally descrtbed in U.S. Patent No. 3 860.003 issued Januarr 1~ 1975 to ~ 40 Buell whtch patent is ir:o.~o~-ted herein b~ refe.e~-e for the .

wo 92110957 2 0 9 7 ~ 2 7 PCr/USgt/09462 purpose o~ d1sclos1ng a p~rt1cularly pref~ d d1aper llO
configurat10n.

The topsheet 112 and b~c~she~t 1I6 of the di-per llO are generally coextensive and at least part1ally peripherally joined together as noted above. Joining of the topsheet 112 and bac~-~eet 116 may be accomplished by a hot-melt adhesive such as Eastobond A3 manufactured by the Eastman Chemical Products Company of Kingsport Ten~JeSSee. The absorbent core l18 has length and o width timensions general1y less than that of the topsheet 112 and bl- -eet 116. The core 118 is interposed between the topsheet 112 and bao~sheet 116 in fixed relationship.

The diaPer llO periphery comorises oppositely disposed first and second ends 122 and l24. The diaper I10 has a first waist portion l42 and a second waist portion 144 extending respectively from the first end 122 and second end 124 of the diaper 110 periphery towards the lateral centerline of the diaper llO a d1stance of about one-f~fth to about one-third the length of the diaper l10. ~he waist port10ns 142 and 144 comprise those portions of the diaper llO whtch when worn enctrcle the waist of the wearer and are generally at the h19hest elevation of the d1aper 110 when the wearer is in the stand1ng position. The crotch 146 of the ttaper llO is that port10n of the dia~er llO
disposed between the first and second waist port10ns 142 and 1~4 and which when worn is positioned bah: ~n the leqs of the wearer.

The absolbent ~core~ is any means for absorbing and retaining liquid body exudates. The abso.~ t core 118 is generally co~pressible conformable and nonirrttat~ng to the skin o~ the wearer. A preferred core 118 has first and second o~poset faces and m~r, if desired be further ere?sed by t1ssue layers. One opposed face of the core 118 is ortented towards the t~ps~Pet 112 and the other opposed face is oriented tow~rds the b-c~heet 116.
the absG.bent core 118 is superimposed on the b~ e~t 1l6 and p~efera~ly toined thereto by any means well kno~n ~n the art such as adhesive bonding. In a part1cularly ~.efe..~J embodiment adhesive bonding is accomDlished by longitudlnal adhesive bands which join the core 118 to the b~ ihe t 116. the b~ eet 116 ~ c~E ~t .

WO 92/10957 ~ J~ t 2a~ PCI/uSgl/og462 is i~pervious to l~qùids a~d p~e~ents liqu1ds absorbed by and contained in the absG.bcnt core 118 fro~ ~ett1ng undergarments cloth1ng bedd1ng and any other ob~ects which contact the diaper 110. As used herein the term ~blc~ he~t~ refets to any barrier disposed outwardly of the core 118 as the diaper 1I0 is worn and which contains absorbed liquids within the diaper llO.
Preferably the bac~ et 116 is a polyolefinic film of about 0.012 to a30ut O.OSI m~ (0.0005-0.002 inches~ in thickness. A
polyethylene film is particularly preferred with a suitable film being manufactured by the Monsanto Company of St. ~ouis Missouri as film Ho. 8020. If desired the ba--- et 116 may be embossed or matte finished to provide a more clothlike appearance or be provided with passages to permit escape of vapors.

The topsheet 112 is compliant tactily pleasing and nonirritating to the wearer s skin. The topshe~t 112 p~ven~s contact of the absorbent core 118 and liquids therein with the skin of the wearer. The topsheet 112 is liquid pervious permitt1ng liqùids to re-dtly penetrate therethrough. As used herein the term ~topsl~et~ refers to any liquid pervious facing which contacts the skin of the wearer wh11e the diaper llO is being worn and prevents the core 118 from cont~cting the sk1n of the wearer. The topsheet 112 may be m~de of woven non: ven spunbonded or carded materials. A prefe.. d tops~eet 112 is carded and thermally bonded by me-ns to those sk111ed in the nDn oven fabrics art. A part1cul-rlY p~e~r.~d topsheet 112 has a weight of about 18 to about 25 grams per s~uare meter a minimum dry tensile strength of about 400 grams per cent1meter in the m chine direction and a wet tensile strength of at least about 55 grams per centi0eter in the cross-machine direct1On.
The diaper 1lO is provided with a fastening s~stem 120 and receiving surface 153 for maintaining the first waist port1On 142 and second waist portion 144 in an overlapping configuration ~hen the diaper II0 is worn so that the diaper llO is secured to the wearer. Thus the diaper 1l0 is f1tted to the wearer and a side closure is formed when the fastening syste- 120 is secured to the receiving surface 153.
-SUBSTITUTE SHE~T

WO 92~10~57 2 ~ 9 7 7 2 7 PCr/US91~0g462 4~
The f~stentng s~ste~ lZO should restst the sep~ratton forces whlch occur durtng the ~e~r1ng period. The term ~separation forces~ refers to forces act1ng on the fastening system 120 and recetving surface 153 ~hich tend to cause serJaration release or ; removal of the fastening system 120 from the receiving surface 153. Separation forces include both shear and peel ~orces. The term ~shear force~ refers to d1stributtve forces acting generally tangential to ths receiving surface 153 and which may be thought of as being generally paral1el to the plane of the substrate of 0 the fastening systeo 120. The tenm ~peel fsrces~ refers to distrtbutive forces act1ng in the generally longitudinal direction and perpendicular to the plane of the receiving surface 153 and fastening system 120 substrates.

;5 Shear forces are ~easured by tensile pulling of the fastening system 120 and receiving surface l53 in opposite directions generally parallel to the planes of the respect1ve substrates.
The method used to determ1ne the resistance of a fastening system l20 and receiving surface }S3 to shear forces is more fully set forth in U.S. Patent No. 4 699 622 issued October 13 1987 to Toussant et al. ~hich patent is i~: porated herein by reference for the purpose of tescr1bing the measurement of shear forces.

Pee1 forces are measured by tensile pulling of the fastening system 120 from the receiving surface 15~ at an included ang1e of about 135-. The ~ethod used to detenmine the resistance of a fastening system 120 and receiving surface 153 to peel forces is more fully set forth in U.S. Patent Application Serial No.
0~/132.281 Issue B~tch No. N87 filed November 18 1987 in the name of Scripps wh1ch applic~tton is in:~ porated herein by refe~-er~e for the purpose of describ1ng the ~easur. !nt of peel forces.

Sep~r~tion forces are typically generated by mov _ nts of the ~ea-er or by the ~e~rer trying to unfasten the dtaper 110.
Generally an infant should not be àble to unfasten or remove a d1~per 110 the infant is wearing nor should the di~per 110 come unfastened in the presr ~e of ordin~ry sep~r~tion forces ~hich occur dur1ng non~al we~ring. I~ ~er an ~dult should be ab1e to re~ove the di~per 110 to change ~t when soiled or check to see if , .
,.....
.

Wo 92/~0957 ~ . PCI~/US9t/09462 so111ng has occu ed Generally the fastentng system 120 ~nd rece1v1ng surf~ce 153 should res1st a peel force of at least 200 gru s preferably at le~st about S00 gra~s and more preferably at least about 700 grams Further~ore the fasten1ng srstem l20 and recetv1ng surface l53 should resist a shear force of at least 500 grams p~efelably at le-st about 7~0 grams and ~ore preferably at least about 1 000 grams The rece1v1ng surface 153 may be disposed ~n a f1rst posit10n an~e~e on the d1aper llO so long as the rece1ving surface 153 arga3es the fasten1ng me-ns to ma1nt-1n the f1rst and second ~aist port10ns lU 1n an overlapping conf1gurat10n For example the rece1v1ng surface 153 may be d1sposed on the outs1de surface of the second wa1st port10n 1 U on the ins1de surface of the f1rst waist port10n 142 or any other postt10n on the d1aper 110 on ~h1ch it 1s d1sposed so as to eng-ge w1th the f-stening system 120 ~he rece1v1ng surface 153 ~ay be 1ntegrtl a d1screte element ~otned to the t1aper 110, or a s1ngle piece of mater1al that is ne1ther dtv1ded or d1scont1nuous w1th an element of the d1-per 110, such as the t~ps~et 112 or bac~eet 116 ~h11e the rece1v1ng su f7ce 153 m-y assu~e v~r10us sizes and shaPes the rece1v1ng surface 153 prefer~ ly comprlses one or ~ore integral patches poslt10ned across the outs1de surface of the second waist port10n lU to allow for max1~um f1t ad~ust~ent at the w~ist of the wearer As illustrated in Figure 6 the receivtng surface 153 is p~efel~ ly an elongate rectangular7y shaped 1ntesral member st_u~ed to the outer surface of the second waist portton lU
A su1table receiv1ng surface 153 is a n~ --n fabric is st1tchbonded or any other type of f1ber or loop matertal w ll kno~n in the art The receiv1ng surface 153 m-y be manufactured fro a var1ety of mater1als wh1ch provide f1ber elements and preferably loops capable of being 1ntercepted and reta1ned by the engagtng means Su1table ~ater1als include ny10n polyester polyprop~lene ~nd comb1nattons of the foregoing A su1t~ble recetvtng s~ r_c~ 153 co~Pr~ses a nu~ber of f1ber loops proJect1ng fro~ a ~oven and ts co _ rc1ally an11able as Scotcho~te brand ~0 nylon ~oven loop Ho FJ3~01 sold b~ the M1nnesota ~1ntng and 2~77,~7 wo 92~0957 PCr/US91/Os462 Manuf~cturing Co~p~ny of St. Ptul ~1nnesot~ Another su1t~ble rece1ving surface 153 comprtses a trtcot h-v1ng a plur~l1ty of nylon ftla~ent loops pro~ect1ng fro~ a nylon back1ng ~nd is com~erctally avai1able from Gllford ~lls of Gn~cnsbGro North Carolina and designated Gllford No 16110 A particularly p~ fe ~.d receiving surface is st1to~- dcd loop m~terial so~d by the Mtlliken Comp~ny of Sp~rtanburg South Caro)ina under Number 970n26 o The fastening system I20 is intendet to eng~ge the comple~ent~r~ recetving surface 153 to provtde a secure fit for the d1~per 110. ~he fasten1ng system 120 m~ compr1se any of the well kno~n conf19urat10ns ut11izet for achlev1ng a slde closure on a disposable diaper 110. The fastening system l20 substr n e is joined to the diaper 110 in sP~ced relationshtD fro~ the receiving me~ns 153 As shown on Figure 6 the f-stentng system 120 is p~eferably disposet on both the first and second longttudtn~l stdes of the d1~per 110. A p~ efel f~J conftgurat10n for the fastentng syste~ 120 mini~tzes any potent1~1 contact beL ~ ~ the prongs of the fastening syste~ 120 and the s~1n of the we-rer A
prefe ed f~sten1n~ s~ste~ 120 d1spos1t10n is a Y-shaped t~pe arrangement descr1bed in det~tl 1n U S P-tent No 3 8~8 594 issued Noveobcr I9 1974 to auell An altern-ttvely prefe ~d f~stentnQ system 120 arr-nge~ent is descrtbed in det-tl in U S
2s Patent No 4 699 622 issued October I~ 1987 to Touss~nt et al both of whtch p~tents are incnr~o ~ted heretn by refele ~e for the purpose of illustrattng v~rious placeoents of the fastening system 120 on the dispos~ble d1~per 110.

The fastening syste~ 120 of Figure 6 has a m~nufacturer s end 156 and an oppositely disposed user s end 158 The manufacturer s end 156 is jotned to the tt-per 110, prefer-bljy in juxtapos1t10n with the first w~ist port10n 142 The user s end IS8 is the free end and is se_u~e~ to the recetvtng surface 153 when the d1~per llO is secured to the we~rer After the d1~per llO 1S f1tted ~bout the ~tst of the we~rer the user s eni 158 of the fasten1ng s~ste 120 is rele~s~bly secured to the rece1v1ng s~ e 153 ~nd prefer bly pos1t10ned on . the seeond ~1st port10n 1 U thereDr c ws1ng the d1~per 110 to . ~ _ , ~

.

. , .

wo 92/10957 ~ Pcr/usgt/os~62 enc1rcle the waist of the wearer The d1aper lI0 h~s nc~ effected a s1te closure The prongs (not sho~n) extend fro~ the fastenlng system 120 of the user s end 1~8 so that the prong engag1ng means intercept the strands of the receiving surface 153 A fastening syste~ 120 and complementary receiving surface l53 which provides a resistance to peel forces in excess of 700 grams and a resistance to shear forces in excess of I 000 gra~s may be constructed as follows according to the specific parameters 0 of the fastening system 120 set forth in the afor~ tioned ~Process of H~nuf~cture ~ The complementary reeei~inq surface 153 used in conjunctlon w1th the fastening system 120 is the aforementioned Hilliken Company No 970026 st1t~hbond~i loop fabric ~5 ~he fastening system 120 is at least about 2 5~ centi0eters (1 inch) in width and ~a~ be of any length wh1ch prov1des a convenient user s end lS8 w1th a length of at least about 3 5 centimeters (1 ~ inches) be1ng prefe et The arr-y of the prongs of fastening srstem 120 compr1ses a m~tr1x having about 26 prongs per square cent1meter (169 prongs per squ-re 1nch) The prongs are p~eferent1ally ortented in substant1~11y the s me d1rect10n and face the user s end 15B of the fasten1ng tape In use the d1aper IlO is applted to the wcarer b~
positioning the f1rst wa1st port10n 142 around the ~earer s bac~
and trawing the remainder of the diaper I10 t~m the legs of the we~rer so th~t the second waist portion 1 U is d1sposed across the front of the wearer The user s ends l58 of the fastening system I20 are then secured to the receiv1ng surface 153 on the outside surface of the second w~1st port10n I U to form a side closure _ . .-- ,.

; ~' , -

Claims (21)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. A method for manufacturing a fastening material having prongs, the method comprising the steps of:

providing a thermally sensitive material;

heating said thermally sensitive material to at least the melting point;

providing a substrate transported in a first direction;

depositing discrete amounts of said thermally sensitive material on said transported substrate;

stretching said discrete amounts of thermally sensitive material in a direction having a vector component parallel to the plane of said substrate;

severing said stretched thermally sensitive material to form prongs having shanks, each of said shanks having a distal end and engaging means thereon; and imparting an azimuthal angle of between about 20 degrees to about 160 degrees to said shanks of said prongs.

2. The method according to Claim 1 wherein said step of imparting an azimuthal angle to said shanks comprises biasing said prongs.

3. The method of Claim 2 wherein said step of imparting an azimuthal angle comprises biasing said prongs while they are newly formed and not yet solidified.

4. The method of Claim 2 wherein said step of biasing said prongs comprises applying a fluid pressure differential in a direction having a vector component perpendicular to said first direction to at least a portion of said prongs.

5. The method of Claim 4 wherein said step of applying a fluid pressure differential comprises flowing a gas from a high-pressure area to a low-pressure area across the substrate.

6. The method of Claim 5 wherein said step of flowing a gas across the substrate comprises providing a substantially laminar flow of gas across the substrate.

7. The method of Claim 6 wherein said step of providing a substantially laminar flow of gas across the substrate comprises flowing a gas through at least one flow amplifier.

8. The method of Claim 6 wherein said step of providing a substantially laminar flow of gas across the substrate comprises using a first and a second flow amplifier such that the discharge of said first flow amplifier is drawn into the suction of said second flow amplifier.

9. The method of Claim 7 or 8 wherein said pressure differential is about 1 psi to about 10 psi.

10. The method according to Claim 2 wherein said step of biasing said prongs comprises subjecting said prongs to gravitational forces.

11. The method of Claim 10 wherein said step of subjecting said prongs to gravitational forces comprises vertically inclining said substrate relative to the horizontal.

12. The method of Claim 11 wherein said step of subjecting said prongs to gravitational forces comprises vertically inclining said substrate at least about 15° relative to the horizontal.

13. The method of Claim 11 wherein said step of subjecting said prongs to gravitational forces comprises vertically inclining said substrate at least about 30° relative to the horizontal.

14. The method of Claim 2 wherein said step of biasing said prongs comprises both applying a fluid pressure differential to said prongs and subjecting said prongs to gravitational forces.

15. The method of Claim 1 wherein said step of imparting an azimuthal angle comprises imparting an azimuthal angle of between about 45° to about 135° to said shanks of said prongs.

16. The method of Claim 1 wherein said step of imparting an azimuthal angle comprises imparting an azimuthal angle of between about 60° to about 120° to said shanks of said prongs.

17. A fastening system for attaching to a complementary receiving surface, said fastening system comprising:
a substrate; and at least one prong having:

a shank joined to said substrate at a base, said shank having a proximal end contiguous with said base and projecting outwardly from said substrate, said shank having a leading angle and a trailing angle, said leading angle being substantially different from said trailing angle, said shank being nonperpendicularly oriented relative to the plane of said substrate, said shank further having an azimuthal angle between about 20° and about 160°; and an engaging means joined to said shank and projecting laterally beyond the periphery of said shank.

18. The fastening system of Claims 17 wherein said shank has an azimuthal angle ranging from about 45° to about 135°.

19. The fastening system of Claims 17 wherein said shank has an azimuthal angle ranging from about 60° to about 120°.

20. An absorbent article comprising:

a topsheet;

a backsheet joined with said topsheet;

an absorbent core positioned between said topsheet and said backsheet; and a fastening system according Claim 17.

21. A fastening system for attaching to a complementary receiving surface, said fastening system manufactured according to the method of Claim 1, 2, 4, 10, or 14.