Abstract: Improvements are disclosed for an apparatus for continuously molding small fastener elements integral with a base web from a flowable resin. The apparatus comprises a cylindrical mold roll rotatable about an axis and defining small fastener element-shaped mold cavities in the surface thereof, and pressure-applying means to apply operating pressure to force the resin into the cavities at a pressure zone. The pressure-applying means and mold roll define a mold gap therebetween for forming the base web. The advantageous use of relatively long mold rolls, to produce a correspondingly wide web, and the use of higher molding pressures, e.g. to form very small fastener elements, is enabled by various improvements, including means to maintain the mold gap at a desired thickness profile across the length of the molding region of the mold roll under operating pressure. In some cases the pressure-applying means includes a pressure roll, in other cases it includes a resin nozzle assembly or pressure head.

Abstract: A fastener tape is provided including (a) a molded resin base sheet with an array of integrally molded fastener elements extending from a first side of the base sheet; and (b) a substrate permanently secured to a second side of the base sheet, the substrate comprising first and second yarns or fibers, the first yarn or fiber comprising a first polymeric material and the second yarn or fiber comprising a second, different polymeric materials, one of the polymeric materials being capable of adhesion to the resin of the base sheet.

Abstract: A method of forming a fastener is provided, including (a) forming, from a thermoformable material, a preform product having a sheet-form base and an array of preform stems integrally molded with and extending from the base to corresponding terminal ends; (b) heating the terminal ends of the stems to a predetermined softening temperature, while maintaining the sheet-form base and a lower portion of each stem at a temperature lower than the softening temperature; and (c) contacting the terminal ends with a contact surface that is at a predetermined forming temperature, lower than the softening temperature, to deform the terminal ends to form heads therefrom that overhang the sheet-form base. Fasteners and other methods of forming them are also provided.

Abstract: A reclosable closure consists of two longitudinally continuous strips and which, when facially engaged, are held together by hook and loop fastening principles. The inner side of one strip has two fields of hook-engageable loops, separated by a female seal profile portion. The inner side of the other strip has two fields of molded hook elements arranged to engage the loops to hold the closure in its closed condition, and a central male seal profile portion for engaging the female seal profile portion to form a seal when the closure is closed. Another reclosable closure is held together by hook and loop fastening principles and includes a resilient bead that is compressed between opposing sides of the closure, or between spaced rails of an opposing side of the closure, when the hooks and loops of the closure are engaged. The closure is useful, for example, as a bag closure.

Abstract: Improvements are disclosed for an apparatus for continuously molding small fastener elements integral with a base web from a flowable resin. The apparatus comprises a cylindrical mold roll rotatable about an axis and defining small fastener element-shaped mold cavities in the surface thereof, and pressure-applying means to apply operating pressure to force the resin into the cavities at a pressure zone. The pressure-applying means and mold roll define a mold gap therebetween for forming the base web. The advantageous use of relatively long mold rolls, to produce a correspondingly wide web, and the use of higher molding pressures, e.g. to form very small fastener elements, is enabled by various improvements, including means to maintain the mold gap at a desired thickness profile across the length of the molding region of the mold roll under operating pressure. In some cases the pressure-applying means includes a pressure roll, in other cases it includes a resin nozzle assembly or pressure head.

Abstract: A fastener member (10) useful for separable engagement with surface fibers of a low-loft, non-woven fabric, or the like, has a base web (12) and a multitude of fastener elements (14) formed with and extending from the base web (12). The fastener elements have a profile that comprises an elongated stem portion (22) adjacent the base web (12) and including at an acute angle to the base. A crook portion (24) is formed on the end of the stem and is directed oppositely to the direction of inclination of the stem, being exposed for engaging a mating fastening member (32). The acute angle of the stem of the elements (14) enables them to flex toward the base. Offset pair of such elements (14) can operatively move in a pincer-type motion to engage fibers (32) and to retain engaged fibers. Other element configurations are disclosed. The fastener member has particular application for fastening of disposable products such as garments and diapers.

Abstract: Fastenings, including stretchy or flexible “zebra-like” and “leopard-like” appearing materials, are disclosed having spaced bands or a distribution islands of molded loop-engageable hooks or molded pre-forms for hooks, between which are bands or regions of different character. Molding is by rigid molds filled from the base region of the stems. In embodiments, linear bands or islands of fastener elements are themselves inextensible in the direction of their extent and comprise multiple rows of fastener elements. For ease of forming a uniform, elastically stretchy or flexible product, the bands or islands of fastener elements extend in the machine direction during manufacture.

Abstract: A method for producing a multiplicity of fastener element molding cavities extending from a mold surface, for molding a plastic product having fastener elements integrally molded with and extending from a product base, and a mold so produced. The mold cavities are formed by depositing multiple layers of plating material on a workpiece in a predetermined pattern selected to produce a desired mold cavity shape, or by depositing a thick stratum of plating material over an array of fastener elements and then removing the fastener elements to leave shaped cavities within the plating material. The mold may be in the form of a roll or belt for continuous processing, or in any form for discrete injection molding. Molds having fastener element cavities defined by rigid cast materials are also disclosed.

Abstract: Improvements for an apparatus for continuously molding small fastener elements integral with a base web from a flowable resin. The apparatus includes a rotating cylindrical mold roll defining small fastener element-shaped mold cavities in its peripheral surface. Resin is forced into the cavities under pressure at a gap between the mold roll and either a pressure roll, a pressure nozzle, or a belt. The improvements compensate for the crowning of the mold roll under high molding pressures, enabling the molding of wider products. Other gap controls include skewing, product thickness feedback, and active roll bending. Some pressure and backup rolls have compliant surfaces for conforming to the mold roll to avoid high contact loads that can damage the cavities.