US20070134465A1 - Hook fasteners and methods of making the same - Google Patents
Hook fasteners and methods of making the same Download PDFInfo
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- US20070134465A1 US20070134465A1 US11/657,217 US65721707A US2007134465A1 US 20070134465 A1 US20070134465 A1 US 20070134465A1 US 65721707 A US65721707 A US 65721707A US 2007134465 A1 US2007134465 A1 US 2007134465A1
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- United States
- Prior art keywords
- lane
- fastener
- lanes
- sheet
- touch fastener
- Prior art date
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Classifications
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/56—Supporting or fastening means
- A61F13/58—Adhesive tab fastener elements
- A61F13/581—Tab fastener elements combining adhesive and mechanical fastening
-
- A—HUMAN NECESSITIES
- A44—HABERDASHERY; JEWELLERY
- A44B—BUTTONS, PINS, BUCKLES, SLIDE FASTENERS, OR THE LIKE
- A44B18/00—Fasteners of the touch-and-close type; Making such fasteners
- A44B18/0046—Fasteners made integrally of plastics
- A44B18/0049—Fasteners made integrally of plastics obtained by moulding processes
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- A—HUMAN NECESSITIES
- A44—HABERDASHERY; JEWELLERY
- A44B—BUTTONS, PINS, BUCKLES, SLIDE FASTENERS, OR THE LIKE
- A44B18/00—Fasteners of the touch-and-close type; Making such fasteners
- A44B18/0046—Fasteners made integrally of plastics
- A44B18/0061—Male or hook elements
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/56—Supporting or fastening means
- A61F13/62—Mechanical fastening means, ; Fabric strip fastener elements, e.g. hook and loop
- A61F13/622—Fabric strip fastener elements, e.g. hook and loop
- A61F13/625—Fabric strip fastener elements, e.g. hook and loop characterised by the hook
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/44—Compression means for making articles of indefinite length
- B29C43/46—Rollers
- B29C2043/461—Rollers the rollers having specific surface features
- B29C2043/465—Rollers the rollers having specific surface features having one or more cavities, e.g. for forming distinct products
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/727—Fastening elements
- B29L2031/729—Hook and loop-type fasteners
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/17—Surface bonding means and/or assemblymeans with work feeding or handling means
- Y10T156/1702—For plural parts or plural areas of single part
- Y10T156/1712—Indefinite or running length work
- Y10T156/1715—Means joining indefinite length work edge to edge
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T24/00—Buckles, buttons, clasps, etc.
- Y10T24/27—Buckles, buttons, clasps, etc. including readily dissociable fastener having numerous, protruding, unitary filaments randomly interlocking with, and simultaneously moving towards, mating structure [e.g., hook-loop type fastener]
- Y10T24/2783—Buckles, buttons, clasps, etc. including readily dissociable fastener having numerous, protruding, unitary filaments randomly interlocking with, and simultaneously moving towards, mating structure [e.g., hook-loop type fastener] having filaments constructed from coated, laminated, or composite material
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24008—Structurally defined web or sheet [e.g., overall dimension, etc.] including fastener for attaching to external surface
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24008—Structurally defined web or sheet [e.g., overall dimension, etc.] including fastener for attaching to external surface
- Y10T428/24017—Hook or barb
Abstract
Methods of making touch fasteners include forming lanes of polymeric material into a sheet-form base and forming discrete elements extending from the sheet-form base. Corresponding touch fasteners are also disclosed.
Description
- This application is a continuation (and claims the benefit of priority under 35 U.S.C. § 120) of pending U.S. patent application Ser. No. 10/666,304, filed Sep. 18, 2003, the contents of which is hereby incorporated by reference herein in its entirety.
- This invention relates to fasteners, in particular to hook and loop type fasteners.
- Arrays of molded male fastener elements, e.g., hooks are often formed integrally with a sheet-form base, to provide a sheet-form fastener component. This component can then be engaged with female fastener elements to form a “hook and loop” fastener. It is generally desirable that the fastener elements have good strength and toughness, so as to provide strong engagement during repeated use of the fastener. In some cases, it is also desirable that the sheet-form base be relatively soft and flexible, e.g., to allow the base to flex with a fabric article to which it is attached and to prevent the edges of the sheet-form component from causing discomfort to the wearer.
- Fastener products such as hook and loop type fasteners find extensive use in personal care absorbent articles including, but not limited, to diapers, training pants, disposable swimwear, incontinence garments and pads, and sanitary napkins.
- One aspect of the invention features, in general, a method of making a touch fastener. The method includes coextruding, side-by-side, a plurality of lanes of polymeric material to form a sheet-form base. The sheet-sheet form base includes a lane of a first polymeric material disposed between two lanes of a second polymeric material, the second polymeric material is different from the first polymeric material. The method further includes molding a plurality of discrete fastener element stems extending outwardly from and integral with the sheet-form base in each of the two lanes of the second polymeric material and forming engageable heads on the stems.
- In some implementations, the method further includes molding discrete fastener element stems extending outwardly from and integral with the sheet-form base in the lane of the first polymeric material. Engageable heads may be formed on the discrete fastener element stems extending outwardly from and integral with the sheet-form base in the lane of the first polymeric material. The shape of the fastener elements extending from the first polymeric material may be different than the shape of the fastener elements extending from the second polymeric material. The height of the elements extending from the first and second polymeric material may be different. A tie layer may be disposed between the lanes of the first and second polymeric material. In some embodiments, the sheet-form base includes more than three lanes and the method further includes arranging the lanes so that lanes of the first polymeric material alternate with lanes of the second polymeric material. In other implementations, the method further includes coextruding a polymeric layer during the coextruding of the side-by-side polymeric lanes, the polymeric layer is disposed on the side opposite the molded fastener element stems. In some embodiments, the method further includes bringing in a polymeric layer as pre-form during the coextruding of the side-by-side polymeric lanes, the polymeric layer is disposed on the side opposite the molded fastener element stems. In yet other embodiments, the method further includes bonding a polymeric layer of material to the sheet-form base opposite the fastener element stems. The coextruding, molding, forming engageable heads and bonding the polymeric layer may be performed continuously.
- Another aspect of the invention features, in general, a touch fastener that includes a sheet-form base having a plurality of lanes of polymeric material including a lane of a first polymeric material disposed between two lanes of a second polymeric material, the second polymeric material different from the first polymeric material. Each of the lanes of the second polymeric material have a plurality of discrete fastener elements comprising stems integrally molded with and extending outwardly from the sheet-form base.
- In some implementations, fastener elements extend outwardly from and integral with the sheet-form base in the lane of the first polymeric material. The first polymeric material may be, for example, an elastomer. The touch fastener may be part of, for example, a personal care absorbent product.
- Another aspect of the invention features, in general, a touch fastener that includes a plurality of lanes of polymeric material, forming a sheet-form base. The sheet-form base includes a lane of a first polymeric material and a lane of a second polymeric material, the second polymeric material includes a foam. Extending outwardly from and integral with the sheet-form base in lanes of the first polymeric material is a plurality of discrete fastener elements including stems.
- In some implementations, fastener elements extend outwardly from and integral with the sheet-form base in the lane of the second polymeric material that includes a foam. The second polymeric material may be, for example, a foamed thermoplastic, a foamed thermoplastic elastomer or a formed thermoset. In other embodiments, the first and second polymeric material alternate. A polymeric layer may be bonded to the sheet-form base on the side opposite the fastener elements. The touch fastener may be part of, for example, a personal care absorbent product.
- Another aspect of the invention features, in general, a method of making a touch fastener that includes coextruding, side-by-side, a plurality of lanes of polymeric material to form a sheet-form base. The method further includes molding a plurality of discrete fastener element stems extending outwardly from and integral with the sheet-form base in lanes of the first polymeric material and forming engageable heads on the stems. The sheet-form base includes a lane of a first polymeric material and a second polymeric material, the second polymeric material includes a foam.
- In some implementations, the method further includes molding discrete fastener element stems extending outwardly from and integral with the sheet-form base in the lane of the second polymeric material that includes a foam. Engageable heads may be formed on the stems. A tie layer may be disposed between the first and second polymeric materials. The foam may be formed by a chemical foaming agent or by injecting gas into the second lane. The foam may be a thermoset.
- Another aspect of the invention features, in general, a method of making a touch fastener that includes bonding a plurality of discrete side-by-side lanes of polymeric material together to form a sheet-form base, molding a plurality of discrete fastener element stems extending outwardly from and integral with the sheet-form base in lanes of the first polymeric material and forming engageable heads on the stems. The sheet-form base includes a lane of a first polymeric material and a second polymeric material, the second polymeric material includes a foam.
- Another aspect of the invention features, in general, a touch fastener, including a plurality of lanes and an adjoining layer of polymeric material to form a sheet-form base, the adjoining layer is below and integral with the plurality of lanes. The sheet-form base includes a lane of a first polymeric material disposed between two lanes of a second polymeric material, the second polymeric material different from the first polymeric material. Extending outwardly from and integral with the sheet-form base, opposite the adjoining layer, in each of the two lanes of the second polymeric material is a plurality of fastener elements. The touch fastener may be part of, for example, a personal care absorbent product.
- Another aspect of the invention features, in general, a method of making a touch fastener that includes forming a composite polymeric sheet from at least two different polymeric materials forming corresponding portions of the sheet and defining a boundary therebetween. The method further includes forming a plurality of discrete fastener elements extending outwardly from at least one exposed surface of the composite sheet, stretching the formed sheet sufficiently to cause one of the portions to permanently deform to a greater extent than the other of the portions and reducing stretch of the sheet to allow differences in stretch response between the two portions to locally distort a shape of the sheet.
- In some implementations, the two different polymeric materials may be coextruded side-by-side, forming a plurality of lanes, including a lane of a first polymeric material disposed between two lanes of a second polymeric material.
- Another aspect of the invention features, in general, a method of making a touch fastener that includes coextruding, side-by-side, a plurality of lanes of at least two different polymeric materials, forming a contiguous polymeric sheet. The method further includes forming a plurality of discrete fastener elements extending outwardly from at least one portion of the sheet, forming an adjoining layer of polymeric material and bonding the adjoining layer to the formed polymeric sheet on a side opposite the fastener elements, forming a composite. Finally, the method further includes stretching the formed composite sufficiently in a lateral direction to cause at least one lane of the polymeric sheet to separate from an adjacent lane.
- In some implementations, the stretching is performed under the application of heat. The adjoining layer may be adhesive coated. In some embodiments, the polymeric material of a lane or lanes may contain an additive to aid, for example, in the separation of the lanes upon stretching.
- Another aspect of the invention features, in general, a touch fastener that includes an undulating composite polymeric sheet with local peaks and troughs. The composite polymeric sheet includes at least two different polymeric materials featuring different degrees of stress. The polymeric materials defining different portions of the sheet and defining a boundary therebetween and extending outwardly from at least one surface of the composite a plurality of molded elements. The touch fastener may be part of, for example, a personal care absorbent product.
- In some implementations, engageable heads are included on the stems. In other implementations, the molded elements extend from both peaks and troughs in the sheet.
- Advantages of the invention may include, for example, providing a stretchable fastener that has strong engagement during repeated use. Other advantages may include, for example, providing a fastener that is relatively soft and flexible, for example, to allow the base to flex with a fabric article to which it is attached and to prevent the edges of the sheet-form component from causing discomfort to the wearer.
- All publications, patent applications, patents, and other references mentioned herein are incorporated by reference herein in their entirety for all that they contain.
- Other features and advantages of the invention will be apparent from the following detailed description, and from the claims.
-
FIG. 1 is a perspective view of a fastener according to one embodiment. -
FIG. 1A is an enlarged cross-sectional view of a portion of the fastener shown inFIG. 1 , taken alongline 1A-1A. -
FIG. 2 is a perspective view of an alternative embodiment. -
FIG. 2A is an enlarged cross-sectional view of a portion of the fastener shown inFIG. 2 , taken alongline 2A-2A. -
FIG. 3 is a diagrammatic view of a process for making a fastener according to one embodiment. -
FIG. 3A is an enlarged diagrammatic view of the portion of the process ofFIG. 3 shown in box A. -
FIG. 4 is a diagrammatic view of a process for making a fastener according to an alternative embodiment. -
FIG. 4A is a perspective view of a fastener made by the process shown inFIG. 4 . -
FIG. 4B is a diagrammatic view of a process for making a fastener according to an alternative embodiment. -
FIG. 4C is a cross-sectional view showing other hook shapes that can be produced by the process shown inFIG. 4B . -
FIG. 4D is a cross-sectional view showing other hook shapes that can be produced by the process shown inFIG. 4B . -
FIG. 4E are side views of other alternative hook shapes. -
FIG. 5 is a perspective view of an alternative embodiment, illustrating a tie layer. -
FIG. 6 is a perspective view of an alternative embodiment, illustrating an adjoining layer. -
FIG. 6A is an enlarged cross-sectional view of a portion of the embodiment shown inFIG. 6 , taken alongline 6A-6A. -
FIG. 7 is a diagrammatic view of a process for making a fastener according to one embodiment. -
FIG. 8 is an enlarged cross-sectional view of a portion of the embodiment shown inFIG. 1 , taken alongline 1A-1A, showingcut line 8A-8A. -
FIG. 8A is an enlarged cross-sectional view of a portion of the embodiment shown inFIG. 8 after cutting alongline 8A-8A. -
FIG. 8B is an enlarged cross-sectional view of another portion of the embodiment shown inFIG. 8 after cutting alongline 8A-8A. -
FIG. 8C shows a prior art fastener with a potentially sharp edge. -
FIG. 8D shows a top view of a fastener having a non-linear cut line. -
FIG. 8E shows a top view of fastener having non-linear lanes. -
FIG. 8F shows a top view of a fastener having lanes of different widths and functions. -
FIG. 8G is a perspective view of a diaper including the fastener ofFIG. 8F . -
FIG. 9 is a perspective view of a fastener including height-differentiation. -
FIG. 9A is an enlarged cross-sectional view of a portion of the fastener shown inFIG. 9 , taken alongline 9A-9A. -
FIG. 9B shows a portion of the fastener shown inFIG. 9A after cutting alongline 9B-9B. -
FIG. 9C shows a portion of the fastener shown inFIG. 9A . -
FIG. 10 shows an enlarged view of another fastener including height-differentiation. -
FIG. 11A shows a perspective view of a fastener including discontinuously molded hooks. -
FIG. 11B shows a perspective view of another fastener including discontinuously molded hooks. -
FIG. 11C shows a perspective view of another fastener including discontinuously molded hooks. -
FIG. 12 shows a perspective view of another fastener including different width lanes. -
FIG. 13 is a perspective view of a fastener with fiber added. -
FIG. 14A is a perspective view of a fastener including longitudinal cavities. -
FIG. 14B is a perspective view of another fastener including longitudinal cavities. -
FIG. 14C shows a perspective view the fastener shown inFIG. 14A after stretching in the machine direction. -
FIG. 14D shows a cross-sectional view of the fastener shown inFIG. 14C , taken alongline 14D-14D. -
FIG. 15 shows a perspective view of a fastener including foam lanes. -
FIG. 15A is an enlarged cross-sectional view of a portion of the fastener shown inFIG. 15 , taken alongline 15A-15A. -
FIG. 15B shows the embodiment illustrated inFIG. 15A , after cutting alongline 15B-15B inFIG. 15A . -
FIG. 16 shows a perspective view of a fastener produced by stretching a fastener similar to the one shown inFIG. 1 in the machine direction. -
FIG. 16A shows a perspective view of another fastener produced by stretching a fastener similar to the one shown inFIG. 1 in the machine direction. -
FIG. 16B shows the fastener ofFIG. 16A with peak hooks engaging loop material. -
FIG. 16C shows the fastener ofFIG. 16A with peak and trough hooks engaging loop material. -
FIG. 16D shows a perspective view of fastener produced by stretching a fastener similar to the one shown inFIG. 1 in the machine direction. -
FIG. 16E is a side view of the fastener ofFIG. 16D . -
FIG. 16F is a side view that shows the fastener ofFIG. 16D with the hooks engaging a loop material. -
FIG. 16G is a perspective view of a pre-fastener product that upon stretching can generate the fastener ofFIG. 16D . -
FIG. 17 shows a perspective view a fastener resulting from stretching a fastener similar to the one shown inFIG. 6 in the machine direction. -
FIG. 18 shows a perspective view of a fastener. -
FIG. 18A shows the fastener ofFIG. 18 after stretching in the cross machine direction. -
FIG. 18B shows the fastener ofFIG. 18A after removal of the adjoining layer. -
FIG. 18C shows a perspective view of a fastener. -
FIG. 18D shows the fastener ofFIG. 18C after removal of the adjoining layer. -
FIG. 1 shows a sheet-form fastener 10, including a plurality of coextruded, side-by-side lanes extending longitudinally in the machine direction (MD), forming a sheet-form base 12. The sheet-form base 12 includeslanes 14 of a first polymeric material disposed in an alternating arrangement betweenlanes 16 of a second, different polymeric material. Molded integrally with and extending outwardly from the sheet-form base 12 in each of thelanes 16 of the second polymeric material are a plurality of fastener hooks 18, as shown in detail inFIG. 1A . Fastener products like these are useful, for example, for creating safe, skin-friendly products. They are also useful, for example, in creating better engaging products with greater stretch in the cross-machine direction (CD). Furthermore, hybrid fasteners with unusual combinations of properties can be engineered which gives the end user more design freedom. For example, skin-friendly products can be created in combination with more aggressive, better engaging hooks. Polymeric material pairs forlanes lane 14 is a polypropylene-based thermoplastic elastomer vulcanizate (e.g., SANTOPRENE® elastomer available from Advanced Elastomer Systems, Akron, Ohio) and a suitable material forlane 16 is polypropylene. Different colors may be used, for example, to differentiate the lanes and to denote the function of each lane. Other additives that improve function or aesthetics may also be used. For example, glow in the dark additives, moisture-detecting additives and thermochromic additives may be used in the sheet-form fastener. -
FIG. 2 shows a sheet-form fastener 11, where all lanes of the first and second polymeric materials include a plurality of integrally molded fastener hooks 18 and 20. Thus, hooks 18 are formed of the second polymeric material, whilehooks 20 are formed of the first polymeric material. The geometry of the hooks can be different in different lanes. In some cases it may be advantageous to have specific hooks on specific regions of the fastener to balance function and safety. For example, aggressive palm-tree hooks can be used in hard lanes and skin-friendly, flat-topped hooks in soft lanes. A fastener like this would have high peel strength, but would also be skin-friendly. This product would be useful, for example, in a diaper application. Another example would be to put flat-topped hooks in lanes of a relatively hard material and palm-tree hooks in the other lane of a relatively hard material. Fastener such as this would be useful, for example, when both high shear and high peel are needed.FIG. 2A shows an enlarged cross-sectional view. Suitable polymers and polymer pairs include those discussed above with reference toFIG. 1 . -
FIG. 3 illustrates a suitable process for forming the sheet-form fasteners shown inFIG. 1 andFIG. 2 . As shown inFIG. 3 ,extruder 22 andextruder 24 pump their respective polymeric materials through theirrespective die connectors roll 30 to form aweb 32 that will define the sheet-form base 12 in the finished product (e.g.,fastener 10 or 11). The die for the first polymeric material is offset from the die for the second polymeric material so that when the materials are coextruded, a plurality of side-by-side lanes are created. Theweb 32 is pulled through the nip betweenroll 30 and a hook-formingroll 34, forming hooks extending from the web, and stripped from hook-formingroll 34 by passing theweb 32 around a strippingroll 36. As shown inFIG. 3A , hook-formingroll 34 includes hook-formingcavities 38. Hook-formingroll 34 is formed of a plurality of etched plates, e.g., as described in Fischer U.S. Pat. No. 4,775,310, the entire disclosure of which is incorporated by reference herein. Additional processing can be applied at niproll 40. For example, additional processing may include forming fiber-engaging plate portions at the distal end of the hooks as described in U.S. Pat. No. 5,953,797, the disclosure of which is incorporated by reference herein. The finished sheet-form fastener up roll 42. -
FIG. 4 illustrates a suitable alternative process for forming the sheet-form fasteners shown inFIG. 1 andFIG. 2 . This process is similar to that described with reference toFIG. 3 , except the twoextruders stream connector 44. Material passes throughstream connector 44 intodie splitter 46. Exiting thedie splitter 46 are alternating, side-by-side lanes which form theweb 32. The fastener product is stripped from hook-formingroll 34 by passing theweb 32 between strippingrolls FIG. 4A shows a portion of a possible product resulting from the process. Typically, the base is, for example, from about 0.001 to about 0.01 inch (about 0.025 mm to about 0.25 mm) thick, the hooks extend, for example, from about 0.005 to about 0.1 inch (about 0.127 mm to about 2.54 mm) above the base and the hooks have a density, for example, of about 250 to about 4000 hooks/inch2 (about 39 to about 620 hooks/cm2). Other suitable processes may be used to form the fastener products. U.S. Pat. No. 6,432,339, the entire disclosure of which is incorporated by reference herein, describes another process that would be suitable if modified to include coextrusion. -
FIG. 4B illustrates another suitable alternative process for forming the sheet-form fastener shown inFIG. 1 andFIG. 2 . In this process, theextruder 200 injects molten plastic directly onto arotating mold roll 202. Multiple lanes of plastic exiting the die produce multiple lanes in the fastener product (not shown). The fastener elements extending outwardly from the sheet-form base can initially be in the form of a lightlycrooked hook 208 or astem 212, as shown inFIG. 4C andFIG. 4D , respectively. After the sheet-form base is stripped frommold roll 202, the shape of the engaging fastener elements may be modified withroll 206, to form a sharplycrooked hook 210 or a disk shapedhead 214, as shown inFIG. 4C andFIG. 4D , respectively.FIG. 4E illustrates other possible engaging fastener element shapes. - We define different polymeric materials to mean polymeric materials of different chemical composition or polymeric materials of nearly the same chemical composition, but with different physical properties. Differing physical properties may arise, for example, from differing polymer chain lengths, differing distribution of chain lengths, microstructure of the polymer, additives, etc. Thus, different polymeric materials not only include polypropylene and a polypropylene-based thermoplastic elastomer vulcanizate (e.g., SANTOPRENE® elastomer), but also two different melt flow grades of polypropylene.
- Adhesion of the alternating
lanes lanes -
FIG. 5 shows an alternative embodiment in which a tie layer is provided tobond lanes form fastener 50 includes a plurality of coextruded, side-by-side lanes lanes lanes lanes -
FIG. 6 shows another embodiment in which a base layer is provided tobond lanes Fastener 54 includes a plurality of coextruded, side-by-side lanes Lanes base layer 56 of polymeric material extending longitudinally in the machine direction underlanes form base 13. U.S. Pat. Nos. 5,518,795 and 5,744,080, the entire contents of which are incorporated by reference herein, describes the preparation of laminate hook fasteners having a similar base layer.FIG. 6A shows an enlarged cross-sectional view. The polymeric material inbase layer 56 bonds well to both of thelanes base layer 56 is, for example, from about 0.00001 to about 0.100 inch (about 0.00025 to about 2.5 mm) or more. -
FIG. 7 illustrates a suitable process for forming the fastener shown inFIG. 5 . This process is similar to the process shown inFIG. 4 , except, in addition to theextruders third extruder 58.Extruder 58 pumps the material of tie layer 52 throughstream connector 60. All material streams come together at die splitter 62, creating a web 64, including tie layer 52 and alternatinglanes roll 30 and hook-formingroll 34, forming hooks extending from the web (not shown), and is stripped from 34 by passing the web 64 between strippingrolls -
FIG. 7 also illustrates a suitable process for forming the product shown inFIG. 6 . The setup for this process is similar to that process shown inFIG. 4 , except, in addition to theextruders third extruder 58. In this case,extruder 58pumps base layer 56 throughstream connector 60. All material streams come together at die splitter 63, creating web 65, including underbase layer 56 and alternatinglanes roll 30 and hook-formingroll 34, forming hooks extending from the web (not shown), and is stripped from 34 by passing the web 65 between strippingrolls -
FIG. 8 is a cross-sectional view of a portion of the sheet-form fastener 10 shown inFIG. 1A , with acut line 8A-8A, indicating where thefastener 10 would be slit to form multiple fasteners. The polymeric material that formslanes 14 is a softer material than the polymeric material that formslanes 16, and thus the edges of the fastener tapes will be soft and skin-friendly.FIG. 8A andFIG. 8B show soft-edge sheet-form fasteners form fastener 10 by cutting alongline 8A-8A.FIG. 8C shows a prior art sheet-form fastener 72, with a relatively hard edge as detected by thehuman finger 70. The cut shown byline 8A-8A can be made by a variety of means known in the art. Examples include, but are not limited to, die cutting, laser cutting, knife cutting, ultra-sonic cutting, air knife, water knife, split line formed by polymers having low adhesion and built-in, perforated split lines.FIG. 8D shows a top view of adiaper tab 74, cut in a non-linear fashion along alane 14 of the relatively soft polymeric material, exposing a soft edge.Lanes 16 of thediaper tab 74 do not need to have the same type of hook on each lane. For example, “aggressive” hooks may be used in the lanes near theouter edge 75 of the diaper tab to create a product with high shear performance and high peel strength, while maintaining a soft edge. Whenlanes 14 are made of a thermoplastic elastomer, the improved stretch in the cross-machine direction can makediaper tab 74 engage better with complementary loop material (not shown) and can make it less likely to be inadvertently removed. A suitable polymeric material is a thermoplastic elastomer vulcanizate (e.g., SANTOPRENE® elastomer). The hardness oflanes 14 may be, for example, from about 45 shore A to about 75 shore D. To make material more sticky, tackifying agents may be used. -
FIG. 8E shows a top view of a portion of adiaper tab 79, with non-linear, alternating lanes.Lanes 14 are formed from a relatively soft material andlanes 16 are formed from a relatively hard material. The sheet-form fastener shown inFIG. 8E can be made by the process shown inFIG. 3A , using traversing dies. Preparing a diaper tab in this manner creates a soft-edge fastener and can eliminate the need for cutting in the machine direction (MD). -
FIG. 8F shows a top view of adiaper tab 81, cut in a non-linear fashion alonglane 14 of a relatively soft, tacky polymeric material, exposing a soft-edge. In addition, thistab 81 has awider lane 80 of the relatively tacky, soft material, disposed between twolanes 16, each without hooks. Thiswider lane 80 can, for example, add additional stretch for better engagement.Wide lane 80 can come into contact with the skin of a baby and can act as an additional anchoring point.FIG. 8G showsdiaper tab 81 attached todiaper 250.Diaper tab 81 is fastened tocomplementary loop material 251 to close thediaper 250. -
FIG. 9 shows yet another embodiment. In this embodiment, sheet-form fastener 76 includes a sheet-form base 12, formed from alternatinglanes lanes 14 is softer than the polymeric material that formslanes 16. Fastener hooks 18 extend outwardly from the harderpolymeric material lanes 16. Suitable materials forlanes 14 may include thermoplastic elastomers (e.g., SANTOPRENE® elastomer). In addition to thelanes 14 being formed from a softer material than thelanes 16, thelanes lanes 14 have height H1 that is greater than height H2 oflanes 16. Generally, height-differentiation can help “shroud” or hide thehooks 18. Height differences in the fastener product can be created by making the appropriatecomplementary mold roll 34.FIG. 9A shows a cross-sectional view of the sheet-form fastener 76 shown inFIG. 9 . Cutting the fastener alongline 9B-9B results in height-differentiated, soft-edge fasteners FIG. 9B andFIG. 9C , respectively. Height-differentiation provides, for example, additional protection of the user's skin against the relatively hard hooks 18 extending outwardly fromlanes 16. Thus, a human finger moving gently across the sheet-form fastener 76 in the cross-machine (CD) direction will be more likely to contact the soft material oflanes 14, rather than the relatively hard hooks 18. Of course, a few hooks may extend above the height of thesoft lanes 14 without significantly reducing the softness and safety of the overall product.Lanes 14 of the relatively soft material may also include hooks (not shown), providing additional height-differentiation and, therefore, additional “soft-touch” and safety. The height-differentiation should not be so large that thehooks 18 cannot engage loops of a female fastener component (not shown) to form a complete hook and loop fastener. -
FIG. 10 shows afastener 73 that featureslanes 16 of a relatively hard material withhooks 18 extending outwardly andlanes 14 of a relatively soft material withhooks 20 extending outwardly. Thehooks hooks 20 extending outwardly from the lanes formed of thesofter material 14 are generally higher than most of the distal ends of the hooks extending outwardly fromlanes 16. Ahuman finger 70 moving gently across such a sheet-form fastener in the cross-machine (CD) direction will be more likely to contact thesoft hooks 20 extending outwardly fromlanes 14, rather than the shorter, relatively hard hooks extending outwardly fromlanes 16. This embodiment provides additional skin-friendliness and safety. The softer hooks 20 may or may not serve the purpose of engaging a corresponding female loop component. For example, thehooks 20 may be replaced by non-engageable stems (not shown). It is generally important that the height-differentiation not be so large that thesoft hooks 20 prevent the harder hooks 18 from engaging the loops of a female component (not shown) to form a complete hook and loop fastener. -
FIG. 11A shows a perspective view of a sheet-form fastener 71 havinghooks 18 that are discontinuously molded onlanes 16. By discontinuously, we mean that there are relativelylarge regions 82 where hooks are absent. Regions of discontinuity may, for example, improve safety by reducing the number of relatively hard hooks. The length of the regions ofdiscontinuity 82, as measured longitudinally in the machine direction (MD) may be, for example, from about 0.005 to about 10 inches (about 0.13 mm to about 254 mm), depending upon the application. -
FIG. 11B shows a perspective view of a sheet-form fastener 84 similar to that shown inFIG. 11A , but withhooks 20 extending fromlanes 14.Hooks 20 may be discontinuously molded on lanes 14 (not shown). -
FIG. 11C shows a perspective view of a sheet-form fastener 88 in whichlanes 14 andlanes 16 are height-differentiated and thehooks 18 are discontinuously molded onlanes 16. -
FIG. 12 shows afastener 94 having a greater degree of stretch as a result of increasing the width of relativelysoft lanes 14 relative to the width oflanes 16. A greater degree of stretch may, for example, increase engagement of the hooks with a loop material (not shown) and may, for example, increase safety and skin-friendliness. The softer the material used forlanes 14, the greater the degree of stretch imparted tofastener 94. -
FIG. 13 shows a sheet-form fastener 112 in which the polymeric material that formslanes 14 is a softer and tackier material than the polymeric material that formslanes 16, and afiber 114 is adhered to thetacky lanes 14. Bonding can be, for example, the result of the inherent tackiness of thelane 14 or can be achieved or enhanced by, for example, the addition of other resinous materials such as curable adhesive. If additional resinous material is used to bond the fiber to the fastener, the resinous material may be cured using UV light, heat or other techniques. Thefiber 114 cause the lanes to be height-differentiated resulting in a skin-friendly soft touch fastener product. The fiber can be cotton or fine denier polypropylene. The bonding agents may be, for example, acrylic or polyurethane. -
FIG. 14A shows a sheet-form fastener 116 havingcavities 120 that extend longitudinally throughlanes 16. The cavities may be un-filled (hollow) or they may be filled with a material. Similarly,FIG. 14B shows a sheet-form fastener 118 withcavities lanes -
FIG. 14 C shows a sheet-form fastener 124, resulting from post stretching after forminghooks 18 in the machine direction. Various structures with different three-dimensional shapes are possible, depending upon the materials used forlanes longitudinal cavities 120. Such a structure can allow for a more skin-friendly hook fastener because many of the hooks are “shrouded” in the three dimensional, rippled structure of the stretched hook fastener. Simply pushing the structure flat exposes more hooks to engage the loops of a loop component (not shown).FIG. 14D shows a cross-sectional view taken in the machine direction, alongline 14D-14D ofFIG. 14C .Hooks 18 form complex angles due to the rippled shape of the underlying structure. These complex angles can allow for, for example, better engagement, better shear strength, improved safety and “soft touch.” -
FIG. 15 shows a sheet-form fastener 96, including a plurality of coextruded, alternating, side-by-side lanes extending longitudinally in the machine direction (MD), forming a sheet-form-base 98. The sheet-form base includes alane 100 of a polymeric material and alane 102 of polymeric foam. A plurality of moldedfastener elements 104 extend outwardly from, and integral with, thelanes 100.Lanes 100 andlanes 102 are height-differentiated, as discussed above. In some instances,lane 100 is made of a thermoplastic polymer andlane 102 is made of a foamed thermoplastic polymer. In other instances,lane 100 is a non-elastomeric thermoplastic polymer, e.g., polypropylene, andlane 102 is made of a foamed elastic polymer, e.g. a polypropylene-based thermoplastic elastomer vulcanizate (e.g., SANTOPRENE® elastomers). -
Lane 102 may be foamed by a variety of methods, including using, for example, a chemical foaming agent (e.g., HYDROCEROL® chemical foaming agent available from Clariant Corporation, Holden, Mass.) or by injecting a gas (e.g., carbon dioxide, nitrogen or others) into the plastic that is to formlane 102.FIG. 15A shows an enlarged cross-sectional view of a portion of the sheet-form fastener 96, taken alongline 15A-15A. In this particular case, a height-differentiated fastener is shown, where the height oflane 102, withfoam voids 106, is greater than the height of thehooks 104 extending outwardly fromlane 100. The fastener shown inFIG. 15A may have lanes of the same height and/or some hooks may be molded inlanes 102. As discussed above, adhesion betweenlanes lanes 100 and 102 (not shown).FIG. 15B shows asoft edge fastener 108, formed from cuttingfastener 96 alongline 15B-15B. - Other methods of forming sheet-
form fastener 96 may be used. For example,lanes 100 withhooks 104 andlanes 102 may be formed in a separate step and bonded together later in the process. Using this method,lane 102 may be, for example, formed of a foamed thermoset plastic (e.g., polyurethane) instead of a thermoplastic. Likewise,lane 100 may be formed of a thermoset. Thermosets may be advantageous when, for example, the products are used in a harsh environment. -
FIG. 16 shows a sheet-form fastener 128 having a three dimensional, ripple-type structure that can result from stretchingfastener 10 shown inFIG. 1 in the machine direction. The three dimensional, ripple-type structure results from the differing physical properties of the materials that make uplanes FIG. 16A and discussed below. Such a ripple-type structure may allow for, for example, a more skin-friendly hook fastener because many of the hooks are “shrouded” in the three dimensional, rippled structure of the stretched hook fastener. -
FIG. 16A shows a three dimensional, ripple-type fastener 150, with alternatinglanes Hooks 152 extend frompeaks 156 inlanes 16, whilehooks 154 extend fromtroughs 158 inlanes 16. This three dimensional, ripple-type structure can result from, for example, stretchingfastener 10 shown inFIG. 1 in the machine direction. In this instance, the thickness of the base changed in a uniform way upon stretching.FIG. 16B shows the fastener ofFIG. 16A engaging aloop material 160 connected to asupport base 162 and illustrates that only hooks 152 on thepeaks 156 of the fastener engage the loop material in response to light force.FIG. 16C illustrates that when more force is applied, thehooks 154 in thetroughs 158 engage as well.FIG. 16C further illustrates rippling of theloop support structure 162 as a result of the differential forces applied to it by the rippled fastener below. -
FIG. 16D shows a three-dimensional, ripple-type fastener 163 withhooks 154 only introughs 158.FIG. 16E illustrates that ahook 154 in atrough 158 is below the level of thepeak 156, resulting in a “soft touch” fastener.FIG. 16F illustrates that with force, hooks 154 engageloop material 160 to form a hook and loop fastener.FIG. 16G shows aprecursor 166 to the fastener shown inFIG. 16D . Thisprecursor 166 containsthick regions 165 withhooks 154 extending from these regions andthin regions 164 with no hooks. Upon stretching, a fastener similar to the one shown isFIG. 16 orFIG. 16A is produced. -
FIG. 17 shows a possible three dimensional, ripple-type structure 132 resulting from stretching the sheet-form fastener 54 withbottom layer 56 ofFIG. 6 in the machine direction. -
FIG. 18 shows a sheet-form fastener 139, includinglanes base layer 56, thebase layer 56 being at least extensible.Lanes 16 have moldedhooks 18 extending outwardly. Sheet-form fastener 140 shown inFIG. 18A is derived from sheet-form fastener 139 by stretchingfastener 139 in, for example, the cross-machine direction (CD). Cross-machine stretching is described by Buzzell, et al. in U.S. Pat. No. 6,035,498, the entire disclosure of which is incorporated by reference. Adhesion betweenlanes interface 136 between the lanes. Upon stretching,lanes interface 136, but remain attached to adjoininglayer 56. Due to separation, theinterface 136 becomes gap 138 (FIG. 18A ). In some instances,structure 140 may curl (not shown), forming a three-dimensional structure. Materials forlanes interface 136 during CD stretching. Thus, generally the two materials are relatively incompatible. Adhesion oflanes bottom layer 56 should be good enough so that the lanes of 14 and 16 do not separate from the adjoininglayer 56. Thestructure 140 allows for, for example, greater flexibility of the fastener product, especially in the out ofplane directions 141. Greater flexibility allows for, for example, good safety and skin-friendliness. Materials that are normally compatible may be made incompatible by additives. Examples of such additives are TEFLON® fluoropolymer and a relatively high loading of clay (e.g., 25%). -
FIG. 18B shows that removal of thebottom layer 56 fromstructure 140 yieldsdiscrete elements -
FIG. 18C shows afastener product 176, including, in addition tolanes lanes bottom layer 56 is below the lanes. Upon stretchinglanes bottom layer 56,discrete units 188,lane FIG. 18D . - A number of embodiments of the invention have been described. For example, some of the lanes may be made of a cross-linkable material. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention Accordingly, other embodiments are within the scope of the following claims.
Claims (20)
1. A touch fastener comprising:
a composite polymeric sheet comprising a plurality of longitudinally extending lanes, each lane joined side-by-side to an adjacent lane; and
a plurality of discrete fastener elements comprising stems extending outwardly from at least one exposed surface of the composite sheet,
wherein the composite polymeric sheet comprises a first lane comprising a first polymeric material and a second lane comprising a second polymeric material comprising a foam.
2. The touch fastener of claim 1 , further comprising an engageable head on a distal end of each stem.
3. The touch fastener of claim 2 , wherein the engageable head is hook-shaped.
4. The touch fastener of claim 1 , wherein the lanes are joined at an interface that comprises the first material and the second material.
5. The touch fastener of claim 1 , further comprising an adhesive bonding the adjacent lanes.
6. The touch fastener of claim 1 , further comprising a third lane comprising a third material different from the first material and second material.
7. The touch fastener of claim 6 , wherein the third lane is disposed between the first lane and second lane, and wherein a first interface comprising the first and third material is defined between the first and third lanes and a second interface comprising the second and third materials is defined between the second and third materials.
8. The touch fastener of claim 1 , wherein the plurality of longitudinally extending lanes are formed by coextrusion.
9. The touch fastener of claim 1 , wherein the foam is formed by a chemical foaming agent.
10. The touch fastener of claim 1 , wherein the foam is formed by injecting gas into the second polymeric material as the second lane is formed.
11. The touch fastener of claim 1 , wherein the second polymeric material comprises a thermoset material.
12. The touch fastener of claim 1 , wherein the composite polymeric sheet comprises a plurality of lanes comprising first and second materials.
13. The touch fastener of claim 12 , wherein the lanes comprising the first and second polymeric materials alternate.
14. The touch fastener of claim 1 , wherein the first polymeric material comprises polypropylene.
15. The touch fastener of claim 1 , wherein the second polymeric material comprises an elastomer.
16. The touch fastener of claim 15 , wherein the elastomer comprises a polypropylene-based thermoplastic vulcanizate.
17. The touch fastener of claim 1 , wherein the second lane has a height that is greater than a height of the first lane, each height being measured from a back surface of the respective lane to the top surface of the respective lane.
18. The method of claim 1 , wherein the at least one exposed surface of the composite sheet defines a portion of a top surface of the first lane.
19. A touch fastener comprising:
a composite polymeric sheet comprising a plurality of longitudinally extending lanes, each lane joined side-by-side to an adjacent lane; and
a plurality of discrete fastener elements comprising stems extending outwardly from at least one exposed surface of the composite sheet,
wherein the composite polymeric sheet comprises a first lane comprising a first polymeric material disposed between a second lane and a third lane, each second and third lane comprising a second polymeric material comprising a foam.
20. The touch fastener of claim 19 , further comprising a fourth and fifth lane, wherein the forth lane is disposed between the first lane and second lane, and wherein the fifth lane is disposed between the first lane and third lane.
Priority Applications (1)
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US9233500B2 (en) | 2010-02-08 | 2016-01-12 | 3M Innovative Properties Company | Method of co-extruding, co-extrusion die, and extruded articles made therefrom |
US10758014B2 (en) | 2011-09-19 | 2020-09-01 | Velcro BVBA | Laminated touch fasteners |
US8685194B2 (en) | 2011-09-19 | 2014-04-01 | Velcro Industries B.V. | Laminated touch fasteners |
US9468203B2 (en) | 2012-02-29 | 2016-10-18 | The Regents Of The University Of California | Microfabricated surfaces for the physical capture of insects |
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US11759085B2 (en) | 2018-05-29 | 2023-09-19 | Unger Marketing International, Llc | Floor cleaning system |
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Also Published As
Publication number | Publication date |
---|---|
CN1874699A (en) | 2006-12-06 |
WO2005027676A1 (en) | 2005-03-31 |
US20050060849A1 (en) | 2005-03-24 |
US7172008B2 (en) | 2007-02-06 |
EP1662928A1 (en) | 2006-06-07 |
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