Abstract: A method of making a fastener product having discrete regions of fastener element stems extending from a strip-form base includes providing a gap formed along a peripheral surface of a rotating mold roll, the mold roll having a plurality of cavities exposed about the peripheral surface. A sleeve is introduced to the gap. The sleeve is positioned about the mold roll and covers selected cavities. Molten resin is introduced to the gap such that the resin forms at least a part of the strip-form base of the product at the peripheral mold roll surface and at least partially fills a plurality of the cavities to form fastener element stems as projections extending from the strip-form base, while the resin remains blocked from said selected ones by the sleeve. The resin is solidified and stripped from the peripheral surface of the mold roll by pulling the projections from their respective cavities.

Abstract: Forming a fastener component having heads constructed to engage loops formed e.g. of fibers of a mating component, comprises 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, by a process having a machine direction and a cross-machine direction. Each molded stem has at least two terminal features spaced from one another in the cross-machine direction, the features having a transverse shape about which engaging fibers can bend, the features having a thickness of about 0.25 mm (0.010 inch) or less, preferably about 0.20 mm (0.008 inch), and for personal care products and the like preferably about 0.1 mm (0.004 inch) or less. The terminal ends of the features are heated to a predetermined softening temperature and the terminal ends are contacted to reform the terminal ends to form heads therefrom that overhang the sheet-form base sufficiently to engage loops.

Abstract: Lightweight, hook-engageable materials capable of functioning as hook-engageable fasteners are treated and configured for use for economical and attractive displays and decorations. Laminates of the material with various substrates with associated printing are used to form visually attractive point of purchase, merchandise or trade show displays. Self-supporting or stable materials having lettering or designs on their surface are used to form banners or floor coverings. Non-woven materials with varied areal density of fibers perform those functions with particular economy. Low density knit fabrics are also useful according to broad features of the invention. Methods are shown to produce reinforced corrugated board and desirably laminated and printed materials having hook-engageable surfaces.

Abstract: Recloseable bags and methods of fabricating recloseable bags.

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: Touch fasteners useful for bags, packaging and other products as well as novel manufacturing of products incorporating such fasteners. A composite touch fastener has a fibrous loop strip partially encapsulated in, or otherwise permanently attached to, resin of a substrate, and an array of loop-engageable fastener elements integrally molded with resin of the substrate. The center portion of the closure seals the bag until it is torn away to expose the mating bands of loops and fastener elements. Methods of applying recloseable touch fasteners, e.g. hook and loop fasteners, to sheet or film include vertical form and fill and horizontal form and fill packaging and pouch making.

Abstract: Methods of forming mold cavities suitable for hook and loop fastening are disclosed, along with effective hook construction and hook and loop fastener products that have an ultrathin cross-section. Photochemical techniques are employed to form plates that define hook-form mold cavities, and, alternatively, chemical etching is employed following preforming of the cavities and machining. Hooks having three-dimensional tapers with enhanced loop engaging characteristics are disclosed. By utilization of special surface finishes and tolerances, hook fasteners, having ultrathin cross-sections are realized, that pave the way for practical use of touch fasteners in a wide range of new areas.

Abstract: Methods of forming a loop product are provided. One method includes (a) needling polymeric fibers through a substrate to form hook-engageable loop structures of the fibers extending from one surface of the substrate; and then (b) using heat and pressure to locally soften and bond polymer of the fibers directly to the substrate and adjacent fibers, thereby anchoring the loop structures to resist fiber pullout under fastening loads.

Abstract: Loop materials are provided for touch fastening. Some loop materials include a flexible sheet-form substrate, and hook-engageable fibers secured individually and directly to the substrate, the fibers being disposed in discrete fastening regions of the substrate, leaving fiber-free substrate between adjacent fastening regions. Methods of making and using such loop materials are also provided.

Abstract: Methods are provided for forming loop fastener products. One method includes applying heat and pressure to a carded web in a manner which fuses fibers on a back side of the web, thereby forming a bonded web, and then embossing the bonded web to raise discrete regions of the web, each raised region containing hook-engageable fiber portions that are exposed for engagement on a front side of the web and fused on the back side of the web within the region. Another method includes placing staple fibers on a back side of a substrate; needling the staple fibers through the substrate to form a composite, thereby forming loop structures extending from a front side of the substrate; applying heat and pressure to the composite in a manner which fuses fibers on the back side of the substrate while protecting the loop structures on the front side of the substrate; and embossing the composite.

Abstract: Loop products are provided that include a carrier sheet having a plurality of holes pierced therethrough, and a layer of fibers disposed on a first side of the carrier sheet, loops of the fibers extending from the holes on a second side of the carrier sheet, bases of the loops being anchored on the first side of the carrier sheet. In some implementations the loop product has an overall weight of less than about 2.0 and wherein the fibers form an overall coverage of at least about 50,000 meters per square meter. In some implementations a majority of the fibers have an individual fiber strength of at least 6 grams and a denier of less than about six.

Abstract: A sheet-form loop product includes a flexible paper substrate and a layer of staple fibers disposed on a first side of the substrate, exposed loops of the fibers extending from holes through the substrate to a second side of the substrate, with bases of the loops being anchored on the first side of the substrate. The loops can be fastening loops. The product is formed by needling the fibers through the paper and then bonding the fibers. Examples include loop fastener materials, towels, abrasive scrubbing pads and sanding materials.

Abstract: Molded male touch fastener components, and methods of making such components are disclosed. Components include multiple, discrete features that extend laterally from a common side of an upper end of a formation, for engagement of loops.

Abstract: A laminate comprising a paper substrate having at least one broad surface to which is laminated a light-weight hook-engageable material or a loop-engageable hook material. The hook-engageable material has a generally sheet-form web body having a first surface laminated to the broad surface of the substrate and a second surface over which hook-engageable fibers or yarns generally extend, the paper substrate having an adhesive material on its side opposite from the low-weight loop material. The laminate is configured to form play, educational or display systems comprising an extended display surface comprised of a first touch fastener surface and objects backed by a second touch fastener surface adapted to mate with the first touch fastener surface, with both the first and second touch fastener surfaces having laminated-sheet form backings.

Abstract: A sheet-form composite has a paper side and a side having a field of fastener hooks. The paper side has a surface formed to be printable, writeable or photo-developable in the presence of the fastener hooks on the obverse side. Weak hook areas enable support of light weight papers upon loop surfaces that are not designed for hook and loop fastening. Selected bands in which hooks reside enable performing other operations in non-hook areas, with which the hooks would interfere, or would be damaged. The composite is useful for display, sales, advertising or adornment, and is readily fed through standard inkjet and other printers. Images are thus acquired and transferred onto the composite by computer.

Abstract: A running length of fastener product is formed of longitudinally pre-oriented synthetic resin. The product is characterized by a base web and an array of discrete fastener elements protruding from at least one side of the web, the web being in a laterally stretched molecular oriented condition. After forming a preform having discrete fastener elements integral with a base web in a stretchable state, the preform is stretched in a manner that substantially increases the fastener element spacing and reduces the thickness of the base web. A machine is shown that is capable of lengthwise orienting before forming and widthwise stretching after forming, which employs controlled heating to render the product widthwise stretchable while preserving or achieving a desired shape of the fastener elements.

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 hook fastener member having rows of molded hook-shaped fastener elements that lie in planes aligned with the rows, with generally planar plate portions at the outermost ends of at least some of the fastener elements, the plate portions lying generally parallel to the base of the fastener member. The plate portions can enhance engagement of the hook fastener members with mating loop fastener members, particularly with low loft non-woven loop fastener members. A method of making fastener members is provided. Molten resin is extruded and applied to a molding roller, creating preforms. The outermost portions of at least some of the preforms are flattened, thereby forming generally plate shaped portions. Disposable absorbent garments advantageously incorporate the hook fastener members.

Abstract: A method of making a fastener product having discrete regions of fastener element stems extending from a strip-form base includes providing a gap formed along a peripheral surface of a rotating mold roll, the mold roll having a plurality of cavities exposed about the peripheral surface. A sleeve is introduced to the gap. The sleeve is positioned about the mold roll and covers selected cavities. Molten resin is introduced to the gap such that the resin forms at least a part of the strip-form base of the product at the peripheral mold roll surface and at least partially fills a plurality of the cavities to form fastener element stems as projections extending from the strip-form base, while the resin remains blocked from said selected ones by the sleeve. The resin is solidified and stripped from the peripheral surface of the mold roll by pulling the projections from their respective cavities.

Abstract: A plastic molded hook for use with a hook and loop fastening system especially adapted for use with low profile loops. The hook design includes a base, a stem and a crook whereby the volume of the portion of the hook penetrating into a pile of loops is defined as the displacement volume. Hooks especially adapted for use with low profile loops have a displacement volume of less than 6×10−6 cubic inches.