US20050151293A1 - Folded fastener products - Google Patents
Folded fastener products Download PDFInfo
- Publication number
- US20050151293A1 US20050151293A1 US11/005,149 US514904A US2005151293A1 US 20050151293 A1 US20050151293 A1 US 20050151293A1 US 514904 A US514904 A US 514904A US 2005151293 A1 US2005151293 A1 US 2005151293A1
- Authority
- US
- United States
- Prior art keywords
- base
- strip
- fastener
- resin
- tab
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
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Images
Classifications
-
- 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
- A44B18/0069—Details
- A44B18/0073—Attaching means
-
- 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
-
- 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
- A44B18/0057—Female or loop elements
-
- 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
- A44—HABERDASHERY; JEWELLERY
- A44B—BUTTONS, PINS, BUCKLES, SLIDE FASTENERS, OR THE LIKE
- A44B18/00—Fasteners of the touch-and-close type; Making such fasteners
- A44B18/0069—Details
- A44B18/0088—Mixed male and female members
-
- 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
- A61F13/5622—Supporting or fastening means specially adapted for diapers or the like
-
- 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
- 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]
-
- 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]
- Y10T24/2708—Combined with diverse fastener
Abstract
Fastener products having a multiplicity of fastener elements extending from a strip-form base, the base including first and second attachment members for attachment of a substrate therebetween, are formed by continuously introducing molten resin to a gap defined adjacent a peripheral surface of a rotating mold roll. The resin forms part of the strip-form base of the product at the peripheral mold roll surface and fills an array of fixed cavities defined in the rotating mold roll to form portions of the fastener elements as projections extending from a first side of the sheet-form base. While the resin is on the mold roll, a sheet material is introduced. The sheet material is folded about a longitudinal fold line to form first and second overlapping fold portions and is introduced under conditions selected to cause the second fold portion to become permanently bonded to resin of the base, while leaving the first fold portion remaining free to be subsequently unfolded from said second fold portion about said fold line. The resin is solidified and stripped from the peripheral surface of the mold roll by pulling the projections from their respective cavities. In some embodiments, a spring section is integrally molded with and extends laterally from a fastening section of the fastener product. The spring section is formed by at least one undulation of the sheet form base that allows the spring section to stretch elastically in a lateral direction upon application of lateral tension to the fastening assembly.
Description
- This invention relates to folded fastening assemblies and method and apparatus for producing and applying the fastening assemblies.
- Fastening assemblies that carry hooks or loops are desirable as part of infant and adult diapers, surgical gowns, and other garments and wraps. Fastening assemblies typically comprise a flexible sheet-form film or non-woven web, that has a tab for connecting to an object and a tape of fastener hook elements secured to a surface of the web, forming a laminate structure. The tab of the fastening assembly is attached to one side of an object and the fastener tape is free to engage a hook-engageable surface formed on an opposite side of the object. The fastener tape is typically made of a synthetic resin that is not stretchable, and the resulting laminate is relatively stiff, does not stretch, and does not present the desired degree of cloth-like feel.
- Fastening assemblies are often formed by laminating the sheet form film or web with a fastener tape and forming a tab for connecting to an object. One typical application for such fastener tabs is for diaper closure systems. The diaper is generally sold with one end of the fastener tab pre-attached to one of the sides of the diaper and the other end of the fastener tab releasably attachable to the other side of the diaper for securing the diaper around a baby.
- It is desirable to provide an economical method of forming fastening assemblies that have a tab and a fastener tape. It is also desirable to provide such assemblies having integral components that achieve desired qualities, such as elasticity, flexibility and low cost and ability to be employed in existing automated assembly systems, such as systems for mass-produced diapers.
- According to one aspect of the invention, a method of forming a fastening product is provided. The fastener product has a multiplicity of fastener elements extending from a strip-form base, the base including first and second attachment members for attachment of a substrate therebetween. The method includes continuously introducing molten resin to a gap defined adjacent a peripheral surface of a rotating mold roll, such that the resin forms part of the strip-form base of the product at the peripheral mold roll surface and fills an array of fixed cavities defined in the rotating mold roll to form portions of the fastener elements as projections extending from a first side of the sheet-form base. The method also includes introducing to the resin on the mold roll a sheet material folded about a longitudinal fold line to form first and second overlapping fold portions, the sheet material introduced under conditions selected to cause the second fold portion to become permanently bonded to resin of the base, while leaving the first fold portion free to be subsequently unfolded from the second fold portion about the fold line. The resin is solidified and stripped from the peripheral surface of the mold roll by pulling the projections from their respective cavities.
- Variations of this aspect of the invention can include one or more of the following features. The folded material is folded about multiple fold lines separating more than two fold members. The second fold portion is bonded to the first side of the base from which the fastener elements extend. The second fold portion is bonded to a second side of the base opposite the first side from which the fastener elements extend.
- In another aspect of the invention a method of forming a fastening assembly includes molding a continuous sheet-form base having a multiplicity of fastener elements integrally molded with and extending from a fastening section of a surface of the base lying generally in a plane. The base, as molded, has a non-planar undulation in which the base extends out of its plane to form a peak that extends along a longitudinal direction of the base with opposite major surfaces of the base remaining generally parallel. The undulation is elastically deformable to enable the base to stretch laterally upon application of a lateral tensile force to the fastener product.
- Variations of this aspect of the invention can include one or more of the following features. The base, as molded, has multiple, parallel undulations, each undulation forming a peak. The undulations are disposed in a region adjacent the fastener elements. The undulations are molded integrally with the fastener section. The undulation is formed by a mating groove and channel of a pair of rolls defining a nip in which the base is formed. The undulation is pre-formed on a material that is introduced into a base forming nip formed by a pair of rolls, the rolls having a mating groove and channel that accommodate the undulation.
- Other variations can include coating the undulation with an elastomer and/or filling an area between adjacent peaks with an elastomer. The elastomer is selected from the group consisting of thermoplastic elastomers, thermoplastic polyurethanes, elastomeric copolymers containing polyethylene terephthalate PET, thermoplastic olefins, and natural or synthetic rubber. The fastener section is molded of resin selected from the group consisting of polyester, polyethylene, polypropylene, polyamide and copolymers and alloys thereof. The method includes forming a tab joined with the base, the tab extending laterally from the undulation along a lateral margin of the fastener assembly opposite a second lateral margin more nearly adjacent the fastening section, the tab comprising at least one flap for joining the fastener assembly to an article. The flap is formed of a section of the base molded integrally with and of the same resin as the portion having the undulation and the fastening section. The flap is formed by folding and permanently joining a portion of the base to another portion of the base. The portion of the base that is folded is thinner than other portions of the base. The Tab is formed by introducing a sheet material into a nip in which the base is molded, the sheet material being folded about a longitudinal fold line to form first and second overlapping fold portions and introduced under conditions selected to cause the second fold portion to become permanently bonded to resin of the base, while leaving the first fold portion free to be subsequently unfolded from the second fold portion about the fold line. The sheet material is bonded to a surface of the base opposite the first surface from which the fastener elements extend. The sheet material is bonded to the first surface of the base from which the fastener elements extend. The second fold portion is bonded to the base only along a margin area of an exposed surface of the second fold portion. Unbonded surface areas of the first and second fold portions are protected from contact with the resin by a protective tape forming a barrier to the resin. Unbonded surface areas of the first and second fold portions are protected from contact with the resin by a protective coating forming a barrier to the resin. The method includes forming dams along edges of the fastening section. The dams are higher than the fastener elements. The step of permanently joining is achieved by heat-staking, adhesive or rf-welding together the portion of the base to the another portion of the base.
- In another aspect of the invention, a method of forming fastener tabs, each tab including a multiplicity of fastener elements extending from a strip-form base and first and second attachment legs for attaching the tab to a garment or substrate therebetween, is disclosed. The method includes continuously introducing molten resin to a gap defined adjacent a peripheral surface of a rotating mold roll, such that the resin forms at least a part of the strip-form base of the product at the peripheral mold roll surface and fills an array of fixed cavities defined in the rotating mold roll to form portions of the fastener elements as projections extending from a first side of the sheet-form base; while introducing a pre-formed material to the resin under conditions selected to cause a portion of the resin to become permanently bonded to the pre-formed material, the preformed material forming at least a part of the strip-form base of the product. The resin is solidified and stripped from the peripheral surface of the mold roll by pulling the projections from their respective cavities. The method further includes folding a portion of the strip-form base to form the first and second attachment legs.
- This aspect of the invention can include any of the variation mentioned herein with respect to other aspects of the invention.
- In another aspect, the invention is a method of forming fastener tabs, each tab including a multiplicity of fastener elements extending from a strip-form base and first and second attachment legs for attaching the tab to a garment or substrate therebetween. The method includes continuously introducing molten resin to a gap defined adjacent a peripheral surface of a rotating mold roll, such that the resin forms at least a part of the strip-form base of the product at the peripheral mold roll surface and fills an array of cavities defined in the rotating mold roll to form portions of the fastener elements as projections extending from a first side of the sheet-form base. The resin is solidified and stripped from the peripheral surface of the mold roll by pulling the projections from their respective cavities. The method further includes folding a portion of the strip-form base to form the first and second attachment legs.
- Variations of this aspect of the invention can include any of the variations mentioned herein with respect to other aspects of the invention.
- In another aspect of the invention, a fastening assembly is provided. The fastening assembly includes a multiplicity of fastener elements integrally molded with and extending from a first surface of a sheet-form base to form a fastening section of the fastening assembly, and a spring section integrally molded with and extending laterally from the fastening section, the spring section formed by at least one undulation of the sheet form base that allows the spring section to stretch elastically in a lateral direction upon application of lateral tension to the fastening assembly.
- Variations of this aspect of the invention can include one or more of the following features. The undulation is coated with an elastomeric resin. The undulation is triangular. The undulation is sinusoidal. The fastening assembly further includes a tab section having a first and a second attachment leg.
- In another aspect, the invention provides a fastener tab including a continuous, unitary strip of thermoplastic resin having first and second end regions, a multiplicity of fastener elements, each having a stem integrally molded with and extending from a surface of the unitary strip disposed in the first end region, and the second end region having two opposable leg portions formed integrally with and of the same material as the continuous strip, the two opposable leg portions positioned to be secured to oppositely directed faces of a substrate or article to support the tab in a manner that the first end may be free to enable its fastener elements to engage a mating surface.
- Variations of this aspect of the invention can include one or more of the following features. The leg portions extend from a common hinge region. The strip of thermoplastic resin has a longitudinal profile configured to define at least one hinge region. The hinge region is defined by a localized reduction in thickness of the strip of thermoplastic resin. Portions of the strip of thermoplastic resin are folded together and permanently joined to define the two leg portions. The continuous strip of thermoplastic resin has at least two spaced apart localized lines of reduced thickness extending longitudinally across the strip to define two hinge regions about which adjacent portions of the strip are folded to constitute the leg portions. The strip, as initially formed, has a substantially longitudinal straight profile with a first hinge region spaced from its adjacent end a first distance and a second hinge region spaced from the end a substantially greater distance, the strip having been bent back upon itself about the second hinge, the bent back portion being permanently joined to the remainder of the strip adjacent to the first hinge region, the outer portion of the strip being free to bend about the first hinge to form an attachment jaw for receiving therebetween a substrate or article to which the oppositely directed surfaces of the respective leg portions may be joined. The bent back portion is permanently joined to the remainder of the strip by adhesive. The bent back portion is permanently joined to the remainder of the strip by ultrasonic bonding. The bent back portion is permanently joined to the remainder of the strip by heat staking.
- In another aspect the invention provides a fastener tab. The fastener tab includes a strip form, unitary body consisting essentially of a contiguous resin, the body having a first end and a second end, hooks in a first end region, and two opposable legs in a second end region spaced apart from the hooks for mounting the fastener tab to opposite sides of a substrate.
- Variations of this aspect of the invention can include one or more of the following features. The second end region includes a first portion, a second portion, and a hinge therebetween. The second end region is folded about the hinge to overlap the first portion and the second portion. The fastener tab further includes at least one of an adhesive, an ultrasonic weld or a heat stake, joining the overlapped first and second portions. The hinge is defined by a section of decreased thickness. The second region further includes a third portion and a second hinge between the second portion and the third portion. The first portion extends generally in a plane defined by the first end region, and the second portion is folded back over the first portion. The first portion extends out of a plane defined by the first end region, and the second portion is folded back over the first portion. One of the two opposable legs comprises an integrally molded portion extending out of a plane defined by the first end region. The second end region includes a first portion extending generally in a plane defined by the first end region, a second portion folded back over the first portion, and a third portion folded back over the second portion. The second portion forms a first of the two opposable legs, and the third portion forms a second of the two opposable legs. The first and second portions are permanently joined by one of adhesive, heat staking, and ultrasonic welding. The body defines a hinge located between the first portion and the second portion. The body defines a hinge located between the second portion and the third portion. The second end region includes a first portion extending out of a plane defined by the first end region, a second portion folded back over the first portion, and a third portion extending generally in the plane defined by the first end region. The third portion forms a first of the two opposed legs, and the second portion forms a second of the two opposed legs. The first and second portions are permanently joined by one of adhesive, heat staking, and ultrasonic welding. Each of the two opposed legs has an inner facing surface including an adhesive. The adhesive includes a pressure sensitive adhesive. The body is formed of a thermoplastic synthetic resin. The resin includes polypropylene.
- In another aspect, the invention provides a roll of fastener tabs joined side-to-side. Each fastener tab includes a strip form, unitary body consisting essentially of a contiguous resin, the body having a first end and a second end, hooks in a first end region, and two opposable legs in a second end region spaced apart from the hooks for mounting the fastener tab to opposite sides of a substrate.
- Variations of this aspect of the invention can include one or more of the following features. The two opposable legs are stored in a flat, open position. Each of the two opposed legs has an inner facing surface including an adhesive. The strip form unitary body further includes a release liner covering the adhesive. The body of each tab has projections extending from a surface opposite the adhesive and arranged to be engaged by the adhesive of an overlapping layer of the roll, to limit inter-tab adhesion. The body of each tab has a silicone coating on a surface opposite the adhesive and arranged to be engaged by the adhesive of an overlapping layer of the roll, to limit inter-tab adhesion.
- Other features and advantages of the invention will be apparent from the following description of embodiments, and from the claims.
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FIG. 1A is a perspective view of a diaper comprising fastening assemblies. -
FIG. 1B is a perspective view of a fastening assembly. -
FIG. 1C is a side, cross-sectional view of the fastening assembly ofFIG. 1B . -
FIG. 1D is an expanded side, cross-sectional view of the area ID ofFIG. 1C . -
FIG. 1E is a side, cross-sectional view of the fastening assembly ofFIG. 1B in compressed state. -
FIG. 1F is a side, cross-sectional view of the fastening assembly ofFIG. 1B in extended state. -
FIG. 2A is a perspective view of a continuous web from which the fastening assembly ofFIG. 1B is cut. -
FIG. 2B is a schematic plan view of a preferred non-woven web for use in the tab ofFIG. 1B . -
FIG. 2C is an enlarged schematic plan view of the face of the non-woven loop material shown inFIG. 2B . -
FIG. 3A is a side view of the apparatus forming the web ofFIG. 2A . -
FIG. 3B is a view of the molding apparatus ofFIG. 3A alongline 3B-3B. -
FIG. 3C is a diagrammatic side view of thenon-woven web 108 alonglines 3C-3C ofFIG. 3A . -
FIG. 3D is a diagrammatic cross-sectional side view of theweb 200 alonglines 3D-3D ofFIG. 3A . -
FIG. 4A is a side view of another apparatus forming the web ofFIG. 2A . -
FIG. 4B is a view of the molding apparatus ofFIG. 4A alongline 4B-4B. -
FIG. 4C is a diagrammatic side view of thenon-woven web 108 alonglines 4C-4C inFIG. 4A . -
FIG. 4D is a diagrammatic cross-sectional side view of theweb 200 alonglines 4D-4D inFIG. 4A . -
FIG. 4E is a view of the post forming apparatus ofFIG. 4A alongline 4E-4E. -
FIG. 5 is a side, cross-sectional view of another fastening assembly. -
FIG. 5A is a side view of an apparatus forming the web ofFIG. 5E . -
FIG. 5B is a view of the molding apparatus ofFIG. 4A alongline 4B-4B. -
FIG. 5C is a diagrammatic cross-sectional side view of thepost processing apparatus 180 alonglines 5C-5C inFIG. 5A . -
FIG. 5D is a diagrammatic cross-sectional side view of thepost processing apparatus 190 alonglines 5D-5D inFIG. 5A . -
FIG. 5E is a perspective view of acontinuous web 300 from which the fastening assembly ofFIG. 5 is cut. -
FIG. 5F is a view of the molding apparatus ofFIG. 5A alongline 5F-5F. -
FIG. 6A is a perspective view of a diaper comprising a belt-type fastening assembly. -
FIG. 6B is perspective view of a belt-type fastening assembly. -
FIG. 6C is a perspective view of acontinuous web 450 from which the belt-type fastening assembly ofFIG. 6B is cut. -
FIG. 6D is a side view of anapparatus folding web 412 ofFIG. 6C and in situ laminating it to a fastening section. -
FIG. 6E is a diagrammatic cross-sectional side view of theweb 450 ofFIG. 6C with a foldedweb 412. -
FIG. 7A is a diagrammatic cross-sectional side view of another fastening assembly. -
FIG. 8 is a perspective view of a diaper including fastener tabs, according to the invention. -
FIG. 9A is a perspective view of the fastener tab ofFIG. 8 . -
FIG. 9B is a side view of the fastener tab ofFIG. 9A . -
FIG. 10 is a highly magnified view of a hook portion of the fastener tab ofFIG. 9A . -
FIG. 11A is a side view of the fastener tab ofFIG. 9A shown in an unfolded state. -
FIG. 1B is a side view of the fastener tab ofFIG. 9A shown in a partially folded state. -
FIG. 12 is a perspective view of a continuous web of fastener tab material stored in roll form. -
FIG. 13A is a side view of the fastener tab ofFIG. 9A shown partially attached to a substrate. -
FIG. 13B is a side view of the fastener tab ofFIG. 9A shown attached to a substrate with the fastener tab in a protected position. -
FIG. 13C is a side view of the fastener tab ofFIG. 9A shown attached to a substrate and in position for use. -
FIG. 14A is a side view of an apparatus for forming a continuous web of fastener tab material. -
FIG. 14B is a front view of a molding/calendaring assembly of the apparatus ofFIG. 14A , taken alongline 14B-14B. -
FIG. 14C is a perspective view of the molding/calendaring assembly ofFIG. 14B shown with a guide roll. -
FIG. 15 is an end view of the continuous web produced by the molding/calendaring assembly ofFIG. 14B . -
FIG. 16 is a perspective view of an alternative embodiment of a continuous web of fastener tab material. -
FIG. 17A is a side view of an alternative embodiment of a fastener tab shown in an unfolded state. -
FIG. 17B is a side view of the fastener tab ofFIG. 17A shown in a folded state. -
FIG. 18 is a side view of an alternative embodiment of a fastener tab. -
FIG. 19 shows a mold roll for forming the fastener tab ofFIG. 18 . -
FIG. 20A is a side view of an additional alternative embodiment of a fastener tab shown in an unfolded state. -
FIG. 20B is a side view of the fastener tab ofFIG. 20A shown in a folded state. -
FIG. 21 shows a mold roll and base roll for forming the fastener tab ofFIG. 20A . -
FIG. 22A is a cross-sectional view of a tape product of side-by-side fastener tab pre-forms. -
FIG. 22B is a cress-sectional view of the fastener tab pre-forms ofFIG. 21A folded to form multiple individual fastener tab products. - Referring to
FIG. 1A twofastening assemblies 100 attach theback side 91 of adiaper 90 to thefront side 93 securing the diaper about a body. - Each
fastening assembly 100, shown inFIGS. 1B and 1C , features afastener tape section 102, a stretchyundulating section 104 and atab section 108, which, in major part, are formed in a single operation as described below. Thefastener tape section 102 includes abase 103 and hook-shapedfastening elements 105 integrally molded with and extending from one surface ofbase 103. The surface of the fastener tape opposite the hooks has embossing or other surface patterns for grasping by the user. Optionally, as shown in the embodiment illustrated inFIGS. 1B-1C , on the hook side of the fastener tape at the left and right edges of thefastener tape section 102 there are two raiseddams base 103.Dams 10 a, 110 b are slightly higher than the hook-shaped fastening elements, serving to shield the hooks from accidentally touching and potentially scratching the skin of a baby or other user. The fastening assembly has a width w of the order of {fraction (1/2)} inch (1.3 cm) and a length l of the order of 4 inches (10.2 cm). Thefastener tape section 102 is of width w and has length l1 of the order of 1 inch (2.5 cm). In one example the hooks are of CFM-29 designation, available from Velcro USA Inc. of Manchester, New Hampshire, U.S.A. The CFM-29 hook strip has hooks of only 0.015 inch (0.38 mm) height, a base thickness t1 of 0.003 inch (0.08 mm) and a fastener element density of the order of 1000 or more fastener elements per square inch. The height of thedams - Other fastener element shapes capable of releasable engagement are also feasible. For example, fastener elements having a mushroom or flat-topped stem shape, a palm-tree shape or any other shape for engaging a loop material are contemplated. Furthermore, fastener elements having shapes capable of releasably engaging other fastener elements of like shape are contemplated as well.
-
Stretchy section 104 extends frombase 103 of thefastener tape section 102 and comprisesundulations 107 formed integrally with the base.Elastomeric resin 106 fills the spaces between theundulations 107 and covers them (FIG. 1D ). Thestretchy section 104 has a length l2 of the order of 1 inch (2.5 cm) and is elastically extensible along the longitudinal direction 120 (FIG. 1B ). Thestretchy section 104 can be extended or compressed, as shown inFIGS. 1F and 1E , respectively, by at least 50% and, preferably, by at least 100%. In certain embodiments, the undulations are triangular shaped (FIG. 1D ), in others, sinusoidal (FIG. 3D ). In one example, the undulations have a height hu of about 0.020 inch (0.51 mm) and a width wu of about 0.025 inch (0.64 mm) in a relaxed state. - Adjacent to the stretchy undulating
section 104 is atab section 108, formed in part of a base 103 a of resin that is integral with theundulations 107 and thefastener section 102. In the embodiment ofFIGS. 1B and 1C , thetab 108 further comprises a folded web that has onearm 108 b in situ laminated to base 103 a and an opposedsecond arm 108 a. The inside surfaces of thetab arms liner 113 which prevents the two arms from adhering to each other. To attach the fastening assembly to thediaper 90 theliner 113 is removed, theside 94 of the diaper is inserted between the twoarms - The
front side 93 of thediaper 90 has a hook-engageable band 80 for engaging thefastener elements 105 of thefastener tape 102, thus attaching theback side 91 of the diaper to thefront side 93 and securing the diaper to the body of a baby (FIG. 1A ). - The fastening assembly of
FIGS. 1B and 1C is formed by cutting sections of acontinuous web 200, shown inFIG. 2A , along the indicatedlines 202. Thecontinuous web 200 is advantageously formed by the process and apparatus illustrated inFIGS. 3A and 3B , now to be described. -
Extruder barrel 51 melts and forces molten plastic 53 through a slot-form die 52. The extruded plastic enters nip 56 formed betweenbase roll 54 andmold roll 55.Mold roll 55 contains a section withmold cavities 59 shaped to form hook-type fastener elements. Left and right of the section with thecavities 59 there aremold ridges dams ridge 61 b on the surface of themold roll 55 and the opposing surface of thebase roll 54 there are cooperating rib andgroove sections 60 shaped to form undulations. The extruded plastic fills thehook cavities 59,ridges section 60, and the further base portion 103 a, all as an integral resin member of a continuous web 200 (FIG. 3D ). - Simultaneously with the molded
plastic 53 forming the hook and undulatingsections pre-formed web 108 enters thenip 56 and forms thetab section 108. In one embodiment, theweb 108 is a non-woven material supplied byroll 40. Theweb 108 passes through guide rolls 41,42 and turningbars FIG. 3C ). The surface of the web forming the inside of the L-shaped fold is coated with abarrier layer 213 preventing the molded plastic from penetrating the non-woven web and fusing both sides of the folded web. The web enters thenip 56 so that onearm 108 a of the L-shaped fold is inserted intoslot 62 formed on themold roll 55 and theother arm 108 b overlaps partially and fuses with the moldedplastic 53 forming thebase 103 along the region 112 (FIG. 3D ). The so-formedcontinuous web 200 travels about a segment of the periphery ofmold roll 55 and is guided by guide rolls 57, 58 topost-processing stages post-processing stage 67 the inside surface of the L-shapedtab 108 is coated with an adhesive 109 and, optionally, aliner 113 is placed between the twoarms Leg 108 a is folded flat toward Subsequently the twoarms bars post-processing stage 68 where the undulations are compressed anddoctor blades 71 apply anelastomeric resin 106 in the spaces between theundulations 107 and coat the tips of the undulations. - The
elastomeric resin 106 is a thermoplastic polymer selected from the group consisting of thermoplastic elastomers, thermoplastic polyurethanes, elastomeric copolymers containing polyethylene terephthalate (PET), thermoplastic olefins, and natural or synthetic rubber. In one embodiment, theelastomeric resin 106 is composed of Santoprene, having an elongation in the range of 50% to 300% and a recovery of at least 75%. - The preformed
web 108 may be a preformed non-woven or knitted loop material. In preferred embodiments, the non-woven loop material is a needled non-woven fabric, that has thickness of the order of 0.05 inch and basis weight of about 2 ounces or less per square yard (68 grams per square meter) (FIG. 2B ). This very thinnon-woven material 108 is dimensionally-stable and has relatively free hook-engageable fibers that extend from at least one side of a continuous, tangled mat offibers 72 that form the web (FIG. 2C ). These fibers have portions available to be engaged by loop-engageable hooks while portions of the fibers at both sides of the engageable portions are secured to the mat of fibers. In present, particularly preferred embodiments, the non-woven needled fabric comprises staple polyester yarns of between about 18 and 4 denier, preferably 6 denier. Following needling of a bat of these fibers, the product, is stretched longitudinally and transversely, to increase its area in excess of 100%, as much as 150% or more from its as-needled condition, following which fibers in the web that engage each other are bonded or adhered together, so that the web has significant tensile strength and the hook-engageable portions of the fibers are well anchored. - In such a fabric the individual fibers of the
mat 72 follow no definite pattern as in a woven or knit product, but extend in various directions within the plane of the fabric mat. The hook-engageable fibers that extend from the non-woven product are of the same fibers that comprise the mat but extend beyond the general mass of themat 72, out of its plane, generally from associatedknots 74, in the form of well anchored loop trees. - In a particular embodiment employing needling followed by stretching, the fibers of the mat are held in their taut, straightened condition by a water-based, acrylic binder applied to the side of the mat opposite the loops to bind the mat fibers in their straight condition to stabilize the areal dimensions of the fabric, and to secure the loops at their associated knots. The binder generally ranges between 20 and 40% of the total weight of the fabric and in the presently preferred embodiments accounts for about one third of the total weight of the non-woven component.
- A description of suitable needled and stretched, hook-engageable non-woven materials is found in pending U.S. patent application Ser. No. 08/922,292, filed Sep. 3, 1997 entitled “Fastener Loop Material, Its Manufacture, and Products Incorporating the Material”, and a related pending Continuation-in-Part application Ser. No. 09/262,159, filed Mar. 3, 1999 entitled “Loop Material for Touch Fastening”, the entire contents of both of which are hereby incorporated by reference.
- For more detail about the general operation of in situ molding methods and apparatus as illustrated, e.g., in
FIG. 3A , and for variations on the process, the reader is referred to U.S. Pat. No. 5,260,015 to Kennedy, et al., which discloses laminates made with loop materials. - The stretchable fastening assembly of
FIGS. 1B, 1C may also be formed by the method and apparatus illustrated inFIG. 4A .Extruder barrel 51 melts and forces molten plastic 53 through a slot-form die 52. The extruded plastic enters thenip 56 betweenbase roll 54 andmold roll 55. As was described above,mold roll 55 contains a section withmold cavities 59 shaped to form hook-type fastener elements and left and right of the section with thecavities 59 there aremold ridges dams dam 110 b a sheet-form portion of the plastic 153 is formed (FIG. 4D ). - Simultaneously with the molded
plastic 53 forming the hook and sheet-form sections aweb 108 folded double enters thenip 56 to form thetab section 108. The inside surfaces of the folded web are separated by afilm layer 212 or tape that prevents molded plastic from penetrating through the web and fusing both sides of the folded web. In one example,layer 212 comprises Teflon tape. The entire backside ofarm 108 b of the folded web is in situ laminated to thebase 103 alongregion 112 as the base is formed. The molded web travels about a segment of the periphery ofmold roll 55 and guided byrolls rolls heated portion 230 of the outside surface ofrolls undulations 60 which soften the sheet-form section 153 of the web and molds undulations 107 in theweb 200. After the formation of the undulations the web passes through apost-processing stage 68 where the undulations are compressed and anelastomeric resin 106 is applied in the spaces between the undulations and on the undulations. - In another embodiment, shown in
FIG. 5 , thefastening assembly 100 features afastener tape section 102, a stretchyundulating section 104 and atab section 108, which is formed by folding a portion of the integrally formedbase sheet 103. The fastening assembly ofFIG. 5 is formed by cutting sections of acontinuous web 300, shown inFIG. 5E , along the indicatedlines 302. - Referring to
FIG. 5A , a method of forming thecontinuous web 300 includes forming a continuous molded web featuring a section with hook-shapedfastener elements 102,dams section 104, as was described above. Next to the undulating section thebase 103 of theweb 300 is extended and asection 179 with reduced thickness is formed havingfold lines FIG. 5B ). The thickness of the molded web is reduced by inserting a ring 172 onto themold roll 55 which reduces the thickness of the gap that establishes the thickness of this section (FIG. 5F ). The molded web travels about a segment of the periphery ofmold roll 55 and guided byrolls post-processing stage 180 where thebase 103 is folded first upward along thefold line 183 then downward alongline 184 and then horizontally along line 185 (FIG. 5C ). The folding produces an inverted V-shapedfold 108 havingarms post-processing stage 180 includes afirst block 181 having a longitudinally extending triangular-shapedstep 188 and asecond block 182 having a triangular-shapedgroove 186 positioned on top of the triangular-shapedstep 188. A narrow gap is formed between thegroove 186 and thestep 188 receiving and folding theweb 300 alonglines web 300 proceeds intonext stage 190 where the two arms of thefold tab 108 integral with thebase 103.Stage 190 includes abase block 191 supporting the web on its surface and aheated block 192 having aslit 193 receiving and pressing thearms FIG. 5D ). The heat melts the plastic sufficiently to fuse the two arms together. Theweb 300 then continues intostage 68 where the undulations are compressed and an elastomeric resin is applied in the spaces between the undulations and on the undulations. - Referring to
FIG. 6A , theback side 91 of adiaper 90 is attached to thefront side 93 by a fastening assembly forming abelt 400. Belt 400 passes throughloops 92, surrounds thediaper 90 and forms aclosure 95. Referring toFIG. 6B , thebelt 400 includes afastening section 410 and anelongated section 420. Thefastening section 410 includeshooks 105,dams undulations 107 providing elasticity to the fastening section 410 (FIG. 6D ). Theback side 411 of thefastening section 410 has embossing or other surface patterns for grasping by the user. Theelongated section 420 comprises anon-woven web 412 which has a portion fused to a portion of the fastening section alongregion 112. - The
belt 400 is formed by cutting segments ofweb 450, shown inFIG. 6C , along indicatedlines 452. Theweb 450 is formed with the method and apparatus shown inFIG. 3A orFIG. 4A . Thenon-woven web 412 is folded formingmultiple folds 414, as shown diagrammatically inFIGS. 6D and 6E , and the folded web is introduced into thenip area 56 where it is laminated in situ to a portion of the molded fastening section. After the formation of the fastening section,web 450 is cut alonglines 452 and folds 414 are unfolded resulting in theelongated section 450 forming thebelt 400. Other features and advantages of the invention may include one or more of the following. - The folded
web 108 may be laminated onto the surface of the fastener tape opposite the surface from which the hook-shaped fastener elements extend (FIG. 7A ). - The adhesive 109 may be activated by ultrasound or ultraviolet light, in which case no
liner 113 is applied. Further thetab 108 may be provided without the adhesive 109 and an adhesive layer may be applied on the surface of the diaper where the fastening assembly is attached during the diaper assembly operation. - Referring to
FIG. 8 , afastener tab 510 is used to secure two components together, e.g., twofastener tabs 510 are shown securing a back 512 of adiaper 514 to afront 516 of the diaper.Fastener tab 510 is attached to diaper back 512 by, e.g., adhesive, and is releasably secured todiaper front 516 by engaging a hook-bearingfastener strip section 520 oftab 510 with a receivingregion 518 on thefront 516 ofdiaper 514. Receivingregion 518 includes, e.g., hook-engageable loops 519. -
Fastener tab 510, shown inFIGS. 9A and 9B , is formed as a flexible, unitary strip of thermoplastic resin, e.g., polypropylene.Tab 510 includesfastener strip section 520, acentral strip section 522, and anattachment section 524.Sections Tab 510 includes acontinuous base portion 530, andfastener strip section 520 includes a plurality of loop-engageable hooks 526 integrally molded with and extending from asurface 528 ofbase portion 530. Referring toFIG. 10 ,hook protrusions 526 are molded in a high density array, as described below, each in the shape of a loop-engageable hook, with, e.g., acrook 527 or mushroom form (not shown). Alternatively, hooks 526 can be initially molded as pre-forms, with the crook or mushroom shapes or other loop-engageable configurations being formed in a post-forming operation, e.g., after the initial molding process. In one example, the hooks are of CFM-29 designation, as previously described.Hooks 526 can be arranged in alternate rows, the hooks facing in opposite directions, as shown inFIG. 10 , or hooks 526 can face in the same direction. -
Fastener strip section 520 terminates in agraspable tip portion 531 devoid of hooks which the user grasps to disengagetab 510 from receivingregion 518 ofdiaper 514 by a peeling motion.Central strip section 522 is devoid of hooks and extends betweenfastener strip section 520 andattachment section 524 to provide a flexible, manipulatable support forfastener section 520.Attachment section 524 includes afirst leg 532 and asecond leg 534 for attaching toopposite sides 555, 556 (FIG. 9B ) of a diaper orother substrate 517. An adhesive 548 on theinside surfaces legs tab 510 tosubstrate 517. - Referring to
FIG. 11A ,legs base portion 530.Base portion 530 inattachment section 524 includes a first portion 570, asecond portion 572, and athird portion 574. Between the first andsecond portions 570, 572 is ahinge 576, and between the second andthird portions hinge 578. To formlegs second portion 572 is folded over first portion 570 athinge 576, formingleg 532, as shown inFIG. 11B .Third section 574 is then folded oversecond portion 572 athinge 578, formingleg 534, as shown inFIG. 9B . First andsecond portions 570, 572 have a reduced thickness, which form recessedsurfaces 580, 582, respectively. First portion 570 is adhered tosecond portion 572 by an adhesive 584, e.g., a rubber based pressure sensitive adhesive, applied to surface 580 or 582 or both. Alternatively,portions 570, 572 are adhered by heat staking, ultrasonic bonding or rf welding. - Referring again to
FIGS. 9A and 9B ,tab 510 has a base thickness, t1, of, e.g., about 0.004 to 0.006 inches, a width, w, of, e.g., about 0.75 to 2 inches, and an overall length, l, of, e.g., about 4 inches. Thegraspable tip portion 531 offastener section 520 has a length, l1, of, e.g., about 0.25 inches, and the remainder offastener section 520 has a length, l2, of, e.g., about 0.875 inches.Central strip section 522 has a length, l3, of, e.g., about 0.75 inches.First leg 532 has a length, l4, of, e.g., about 0.875 inches andsecond leg 534 has a length, l5, of, e.g., about 0.75 inches. - Referring to
FIG. 12 ,fastener tabs 510 are initially formed as acontinuous web 700 from which individual fastener tabs are separated along the indicatedlines 702.Web 700 is provided in aroll form 704 withattachment section 524 in the partially folded position ofFIG. 11B . To limit adherence of adhesive 548 tobackside 710 ofweb 700 and thus aid in release and unrolling ofweb 700,backside 710 is treated with a release coating, e.g. a fluorine or silicone based coating, in anarea 711 that corresponds to adhesive 548. In use, referring toFIGS. 13A-13C , anindividual tab 510 is removed fromweb 700, e.g., by cuttingweb 700 alongline 702, and attached to the diaper orother substrate 517 by contacting the adhesive bearing insideface 550 ofleg 532 to oneside 555 of the substrate whiletab 510 is in the partially folded position ofFIG. 11B .Fastener strip section 520 andcentral strip section 522 are then folded in the direction of arrow C (FIG. 13B ) untilhooks 526 offastener strip section 520 contact theopposite side 556 ofsubstrate 517. This folding motion of the unattached portion oftab 510 brings theadhesive bearing surface 552 ofsecond leg 534 into contact with theopposite side 556 ofsubstrate 517, and hooks 526 into loose engagement with the material ofsubstrate 517. Alternatively, adhesive 548 is omitted, and another fastening technique, e.g., heat staking or ultrasonic or rf welding using the self-adhesive properties of the surfaces being joined, is employed to attachlegs substrate 517. - With
attachment legs substrate 517, andfastener strip section 520 andcentral strip section 522 folded oversubstrate 517,tab 510 is in a protected position for further processing, packaging, and shipping of the diaper or other substrate. A user of the diaper or substrate unfolds fastener strip section 520 (FIG. 13C ) to presenthooks 526 for use in securing the diaper about a wearer, or otherwise using the substrate for its intended purpose. - Referring to
FIGS. 14A-14C ,continuous web 700 is formed by anextrusion apparatus 801 including a molding/calendaring assembly 303 andpost-processing stages 805.Assembly 803 includes anextruder barrel 800, a slot-form die 804, abase roll 808, amold roll 810, a take-off roll 830, and aguide roll 832. Referring particularly toFIG. 14B ,mold roll 810 includes, e.g., two sets of side-by-side tab forming formations, A and B, which produce two bands A′, B′ of tabs 510 (seeFIG. 15 ).Mold roll 810 has anarrow ring 815 of increased diameter shaped to create a separation groove T (FIG. 15 ) between bands A′ and B′. Groove T is an integral, relatively thin, rupturable joint which permits easy separation of bands A′ and B′.Roll 810 has twosections adjacent ring 815 that definemold cavities type fastener elements 526. Next to moldcavity sections mold roll 810 has outer calendaring surfaces 813, 813′ includingsections thickness sections 580, 582 intab 510. Near the center and edge ofsections rings mold roll 810, shaped to form hinges 576, 578, respectively.Base roll 808 is provided with a relatively smoothouter surface 809, e.g., to provide a tab surface suitable to receive a release coating.Rolls distance 820 to formbase 530 of a desired thickness. - In use,
extruder barrel 800 melts the resin and forces the molten plastic through slot-form die 804, to form a sheet-form extrudate ofmolten plastic 802. The extrudedplastic 802, while still molten, enters a nip 806 formed betweenbase roll 808 andmold roll 810. Due to pressure applied at the nip byrolls hook cavities 812, and, by filling thegap 820 between therolls base portion 530 and the various recessed and hinged portions, all as an integral, continuous, thermoplastic web. - As shown in
FIGS. 14A and 14C , upon exiting nip 806, the formed web travels about a segment of the periphery ofmold roll 810 while it cools (mold roll 810 having provision for internal cooling) and then, with the aid of take-off roll 830, the web disengages from the mold roll in a peeling action with the hook-form elements undergoing temporary elastic deformation as they exit from the mold cavities. Then, guided byguide roll 832, the web enters apost-processing stage 850 where adhesive 584 is applied to one or both ofsurfaces 580, 582. - The molded web then passes to a second
post-processing stage 860, where the continuous webs of fastener tab profiles A′ and B′ are separated along line T. Further processing of the symmetrical webs A′ and B′ is identical. For simplicity, further treatment of a single fastener tab profile will therefore be described. The web next passes throughstage 870 where the web is folded along the relativelythin hinge line 576 which lies betweensections 570, 572 untilsections 570, 572 are adhered together. Alternatively, after the web separation ofstage 860 and the folding ofstage 870 are performed,sections 570, 572 are joined by heat staking, ultrasonic bonding or rf welding, employing the adhesive qualities of the thermoplastic resin of which the tabs are formed. - The molded, folded web then passes to
post-processing stage 880 where adhesive 548 is applied tosurfaces stage 880 and the application of adhesive 548 are omitted, and adhesive or other fastening techniques are used after shipment of thefastener tabs 510 to the diaper manufacturer, prior to attachment to a diaper,e.g. fastener tab 510 is attached to a diaper or other article without the use of adhesive, e.g., by heat staking or ultrasonic or rf welding, using the self-adhesive properties of the surfaces being joined. The continuous web of fastening tab material is then wound into roll form 704 (FIG. 12 ) atpost-processing stage 890 for shipment to diaper manufacturers. - For example, as shown in
FIG. 16 , a distribution of protrudingformations 712 is formed onbackside surface 710 of the web to reduce the area of contact between adhesive 548 and thebackside surface 710 to aid in release and unrolling of the web. To formformations 712, theouter surface 809 ofbase roll 808 is provided with a grained texture, not shown, suitable to form moldedformations 712. - Referring to
FIGS. 17A and 17B , afastener tab 510′ includes afirst hinge line 537′, asecond hinge line 536′ separating a thinnedportion 540′ into first andsecond parts 542′ and 544′, respectively, and athird hinge line 538′. At a post-processing stage, e.g., after the molding/calendaring process, asecond attachment leg 534′ oftab 510′ is formed by applying adhesive 541′ alongsurface 543′ offirst part 542′ orsurface 545′ ofsecond part 544′ or both, and folding thinnedportion 540′ atsecond hinge line 536′ to adherefirst part 542′ tosecond part 544′. Alternatively, adhesive 541′ is omitted andfirst part 542′ is joined tosecond part 544′ by heat staking or ultrasonic bonding, using the self-adhesive properties of the surfaces being joined. The portion ofbase 530′ betweenthird hinge line 538′ andfree end 546′ forms afirst leg 532′.Second leg 534′ is folded open by folding aboutfirst hinge line 537′ for further processing, storage, and shipping or folded closed aboutthird hinge line 538′ for attachment to a substrate. - In another embodiment, shown in
FIG. 18 ,fastener tab 610′ has first and second integrally formedlegs 632′, 634′, produced without folding, and hingelines 632′, 634′. Referring toFIG. 19 ,leg 634′ is molded using a mold roll 608′ with a leg formingmold cavity 633′ to createsecond leg 634′ andmold ridges 616′, 618′ which formhinge lines 636′, 638′, respectively.Leg 632′ is formed by the calendaring effect, using a process similar to that described above.Second leg 634′ opens by folding aboutfirst hinge line 636′ for further processing, storage, and shipping or closes by folding aboutsecond hinge line 638 for attachment to substrate. In this embodiment,second leg 634′ typically has a length, l, of, e.g., about 0.25 inches. - Referring to
FIGS. 20A and 20B , afastener tab 710′ includes afirst hinge line 737′, asecond hinge line 736′ separating a thinnedportion 740′ into first and second parts 742′ and 744′, respectively, and athird hinge line 738′. In this embodiment, thinnedportion 740′ is molded/calendared in a partially pre-folded condition. To form the partial pre-fold, as shown inFIG. 21 , amold roll 720′ has a recessedportion 733′ and apressure roll 708′ has a corresponding raisedportion 731′ that, acting together in the above described molding/calendaring process, produce a thinnedportion 740′ having an inverted V-shaped fold. At a post-processing stage, e.g., after the molding/calendaring process, asecond attachment leg 734′ of the tab is formed by applying adhesive 741′ alongsurface 743′ of first part 742′ orsurface 745′ ofsecond part 744′ or both, and folding partially pre-folded thinnedportion 740′ atsecond hinge line 736′ to adhere first part 742′ tosecond part 744′. Alternatively, adhesive 741′ is omitted and first part 742′ is joined tosecond part 744′ by heat staking or ultrasonic bonding, using the self-adhesive properties of the surfaces being joined. Theportion 739′ betweenthird hinge line 738′ andfree end 746′ forms first leg 732′.Second leg 734′ is folded open by folding aboutfirst hinge line 737′ for further processing, storage, and shipping or folded closed aboutthird hinge line 738′ for attachment to a substrate. -
FIGS. 22A and 22B illustrate stages of the side-by-side simultaneous production of six fastener tabs. The dimensions are not to scale, and particularly, the thickness of the material has been exaggerated for ease of illustration. Referring toFIG. 22A , fastener tab pre-forms (TP1-TP6) are initially produced as anintegral tape 900. Each tab pre-form has agraspable tip portion 902, a fastenerelement bearing portion 904 and atab attachment portion 906. Underlying the entire width ofweb 900 is a backing web 908.Tip portion 902 and fastenerelement bearing portion 904 are extruded and molded integrally from the same material onto web 908. The heat and pressure of the molding operation, described below, laminates the molded tip and fastener element-bearingportions integral tape 900. - In one example, each of the six tab pre-forms TP1-TP6 has a
tip portion 902 with a width, wt, of approximately {fraction (1/8)} inch (3.2 mm), a fastener element-bearingportion 904 with a width, wf, of approximately {fraction (5/8)} to {fraction (7/8)} inch (15.9-22.2 mm), and atab attachment portion 906 with a width, wa, of approximately 2 and ⅝ to 3 and {fraction (1/8)} inches (66.7-79.4 mm). - Underlying web 908, for example, is a film of polypropylene or polyethylene or a spun-bond nonwoven web of polypropylene or polyethylene or a laminate of a combination of these materials. Web 908 can also be of other materials such as an elastically stretchy nonwoven loop material that is releasably engageable by fastener element-bearing
portion 904. In one example, the thickness, tw, of web 908 is approximately 0.003-0.006 inch (0.08-0.15 mm) the molded, laminated material of the tip and fastener element-bearingportions -
Tape 900 is initially slit along lines C2 and C4 to provide three fastener tape pre-form webs, each including a pair of fastener pre-forms across its width, i.e., pairs TP1-TP2, TP3-TP4, and TP5-TP6 are formed. As the fastener pre-forms are further processed, each of the pairs are slit along lines C1, C3 and C5, leaving individual pre-forms PT1-PT6. Each individual pre-form is folded and partially adhered to itself in a process similar to that described above with reference toFIGS. 11A and 11B . The resulting fastener tabs T1-T6 are illustrated inFIG. 22B . Again, the dimensions are not to scale and, particularly, the thickness of the base portion and folded portions is exaggerated for ease of illustration. Fastener tab products T1-T6 are shown withattachment flap 910 in a partial closed position, ready for attachment to e.g., a garment or substrate, in the manner described above with reference toFIG. 9B . Also, each continuous length of fastener tab products T1-T6 can be rolled for storage with or without a layer of adhesive provided for attachment, in the manner described above with reference toFIGS. 12 and 16 . - The method of producing the side-by-side preform tab of
FIG. 22A employs the same basic principles of that described above with reference toFIG. 14C . However, the addition of the backing web, eliminates the need to provide extruded molten material over the entire width of the forming nip. Instead, the exposed surface of thetip portion 902 and the fastener elements of the fastener element-bearingportion 904 are formed as bands of molten material introduced into the nip simultaneously with the backing material 908. Such a technique of in-situ laminating and molding bands or islands of material to an initially separate, second material is discussed in greater detail in co-pending U.S. application Ser. No. ______, filed Mar. 14, 2001 and entitled “Hook and Loop Fastening”, the entire contents of which is hereby incorporated by reference. - Other features and advantages of the invention will be realized from the disclosure and drawings, and are within the scope of the following claims.
Claims (23)
1-30. (canceled)
31. A method of forming fastener tabs, each tab comprising a multiplicity of fastener elements extending from a strip-form base and first and second attachment legs configured to attaching the tab to a garment or substrate placed between the legs, the method comprising:
continuously introducing molten resin to a gap defined adjacent a peripheral surface of a rotating mold roll, such that the resin forms at least a part of the strip-form base the peripheral mold roll surface and fills an array of cavities defined in the rotating mold roll to form portions of the fastener elements as projections extending from a first side of the strip-form base;
solidifying the resin;
stripping the solidified resin from the peripheral surface of the mold roll by pulling the projections from their respective cavities;
folding a portion of the strip-form base to form said first and second attachment legs; and
segmenting the strip-form base to define multiple fastener tabs.
32-75. (canceled)
76. The method of claim 31 , further comprising, while
while continuously introducing the molten resin to the gap, introducing a pre-formed material to the resin under conditions selected to cause a portion of the resin to become permanently bonded to the pre-formed material, such that the preformed material also forms part of the strip-form base.
77. The method of claim 76 , wherein the folded portion of the strip-form base comprises at least a portion of the pre-formed material.
78. The method of claim 31 , wherein the folded portion of the strip-form base is folded about multiple fold lines separating more than two regions of the strip-form base.
79. The method of claim 31 , further comprising forming a non-planar undulation in which the base extends out of its plane to form a peak that extends along a longitudinal direction of said base with opposite major surfaces of the base remaining generally parallel, the undulation being elastically deformable to enable said base to stretch laterally upon application of a lateral tensile force.
80. The method of claim 79 , wherein non-planar undulation is molded in the gap.
81. The method of claim 79 , wherein the base has multiple, parallel undulations, each undulation forming a peak.
82. The method of claim 79 , wherein the undulation is pre-formed on a material that is introduced into the gap with the resin.
83. The method of claim 79 further comprising coating the undulation with an elastomer.
84. The method of claim 31 further comprising permanently joining two regions of the folded portion of the base to retain the base in its folded state.
85. The method of claim 84 , wherein the two regions of the folded portion are permanently joined by adhesive.
86. The method of claim 84 , wherein the two regions of the folded portion are permanently joined by ultrasonic bonding.
87. The method of claim 84 , wherein the two regions of the folded portion are permanently joined by heat staking.
88. The method of claim 31 , wherein folding the portion of the strip-form base comprises forming three longitudinal fold lines, with a middle one of the fold lines disposed between an inner fold line adjacent the projections and an outer fold line.
89. The method of claim 88 , wherein folding the portion of the strip-form base further comprises bringing the inner and outer fold lines together, to form the first attachment leg extending out of a plane formed by the strip-form base, with the middle fold line disposed at a distal end of the first attachment leg.
90. The method of claim 31 , wherein folding the portion of the strip-form base comprises forming two spaced-apart, longitudinal fold lines defining a middle base section therebetween, and overlapping the folded portion of the strip-form base to form a three-layer region of the base, with the middle base section between two other sections of the base.
91. The method of claim 31 , wherein the folded portion is folded along a hinge defined by a region of the base of decreased relative thickness.
92. The method of claim 31 , further comprising unfolding a fold of the folded portion to dispose the attachment legs in a flat, open position.
93. The method of claim 92 , further comprising applying an adhesive to an exposed surface of both attachment legs.
94. The method of claim 93 , further comprising placing a release liner over the adhesive on the attachment legs.
95. The method of claim 31 , wherein the projections, as molded, comprise functional fastener elements.
Priority Applications (1)
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US11/005,149 US20050151293A1 (en) | 2000-03-14 | 2004-12-06 | Folded fastener products |
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US09/808,645 US6827893B2 (en) | 2000-03-14 | 2001-03-14 | Folded fastener products |
US11/005,149 US20050151293A1 (en) | 2000-03-14 | 2004-12-06 | Folded fastener products |
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US09/808,645 Division US6827893B2 (en) | 2000-03-14 | 2001-03-14 | Folded fastener products |
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EP (1) | EP1265508A2 (en) |
JP (1) | JP2003526427A (en) |
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AU (1) | AU2001245717A1 (en) |
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Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
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US8966721B2 (en) | 2012-04-18 | 2015-03-03 | Disney Enterprises, Inc. | Adhering fastening strip with grip area |
WO2019155404A1 (en) * | 2018-02-09 | 2019-08-15 | 3M Innovative Properties Company | Reinforced fastening tabs |
CN111698978A (en) * | 2018-02-09 | 2020-09-22 | 3M创新有限公司 | Reinforced fastening tab |
Also Published As
Publication number | Publication date |
---|---|
AU2001245717A1 (en) | 2001-09-24 |
JP2003526427A (en) | 2003-09-09 |
WO2001067912A3 (en) | 2002-06-13 |
US20020023321A1 (en) | 2002-02-28 |
CN1427706A (en) | 2003-07-02 |
CN1232238C (en) | 2005-12-21 |
CA2403309A1 (en) | 2001-09-20 |
EP1265508A2 (en) | 2002-12-18 |
WO2001067912A2 (en) | 2001-09-20 |
US6827893B2 (en) | 2004-12-07 |
MXPA02009084A (en) | 2003-12-11 |
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Legal Events
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AS | Assignment |
Owner name: VELCRO INDUSTRIES B.V., NETHERLANDS ANTILLES Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:CLUNE, WILLIAM P.;REEL/FRAME:016300/0965 Effective date: 20010601 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |