Abstract: Methods of making a sheet-form loop product are provided. One method includes placing a layer of staple fibers against a first side of a substrate comprising a nonwoven web; needling fibers of the layer through the substrate by penetrating the substrate with needles that drag portions of the fibers through the substrate, leaving exposed loops of the fibers extending from a second side of the substrate; and anchoring fibers forming the loops by fusing the fibers to each other and to filaments of the nonwoven web on the first side of the substrate, while substantially preventing fusion of the fibers on the second side of the substrate.

Abstract: Methods of forming a loop product are provided. Methods include needling polymeric fibers through a substrate to form hook-engageable loop structures of the fibers extending from one surface of the substrate and then using heat and pressure to 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. Loop products are also provided.

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: A medical wrap includes a flexible, sheet-form substrate with a discrete medical function delivery region having a surface adapted to be placed against a patient's skin to provide a desired medical effect. The substrate carries a field of fibers exposed on one side thereof for engagement by fastener elements, and an array of fastener elements extending from a side of the substrate opposite the exposed fibers. The fastener elements each have a respective stem extending integrally from a film of resin disposed in a band across the substrate and encapsulating surface features of the substrate. The fastener elements are constructed to snag the exposed fibers when the substrate is wrapped about a patient in an overlapping manner, to secure the wrap about the patient with the medical function delivery region in a desired position. The wrap is useful as a hot or cold pack, medical dressing or drug delivery device.

Abstract: A method of forming a medical wrap including a flexible, sheet-form substrate with a discrete medical function delivery region having a surface adapted to be placed against a patient's skin to provide a desired medical effect. The substrate carries a field of fibers exposed for engagement by an array of fastener elements. The fastener elements each have a respective stem extending integrally from a band of resin extending along the substrate. The fastener elements are constructed to snag the exposed fibers when the substrate is wrapped about a patient in an overlapping manner, securing the wrap about the patient with the medical function delivery region in a desired position. The wrap is configured for use as a hot or cold pack, a medical dressing, or drug delivery device.

Abstract: A material for covering a surface of a home or building is provided in the form of a flexible laminate having a fastening side comprising a sheet-form fastener component, and an opposite side formed by a sheet of paper laminated to the fastener component to increase the dimensional stability of the fastener component for covering and fastening over a wide area. The fastener component can have either hooks or loops. The laminate is particularly useful for laying flooring with low backlash between adjacent pieces.

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: Methods of making a sheet-form loop product are provided. One method includes placing a layer of staple fibers against a first side of a substrate comprising a nonwoven web; needling fibers of the layer through the substrate by penetrating the substrate with needles that drag portions of the fibers through the substrate, leaving exposed loops of the fibers extending from a second side of the substrate; and anchoring fibers forming the loops by fusing the fibers to each other and to filaments of the nonwoven web on the first side of the substrate, while substantially preventing fusion of the fibers on the second side of the substrate.

Abstract: Methods of forming a loop product are provided. Some methods include (a) introducing a sheet-form substrate and a layer of polymeric fibers into a needle loom, with the fibers disposed on a first surface of the substrate, and (b) needling the fibers through the substrate to form hook-engageable loop structures of the fibers extending from a second surface of the substrate through holes formed in the substrate by the needling. Needling the fibers includes piercing the substrate with a plurality of needles while advancing the substrate in a machine direction at a predetermined speed, while cyclically advancing the needles in the machine direction, during piercing of the substrate, in a manner that causes the needles to travel in a substantially elliptical path, such that while the needles extend through the substrate the needles are moving in the machine direction.

Abstract: A method of forming a medical wrap including a flexible, sheet-form substrate with a discrete medical function delivery region having a surface adapted to be placed against a patient's skin to provide a desired medical effect. The substrate carries a field of fibers exposed for engagement by an array of fastener elements. The fastener elements each have a respective stem extending integrally from a band of resin extending along the substrate. The fastener elements are constructed to snag the exposed fibers when the substrate is wrapped about a patient in an overlapping manner, securing the wrap about the patient with the medical function delivery region in a desired position. The wrap is configured for use as a hot or cold pack, a medical dressing, or drug delivery device.

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: A molded plastic hook fastener component for hook and loop fastening has individual raised bases distributed over a common area, each carrying an individual hook element while a laterally contiguous portion of each raised base raises the lower bound for the loop region beneath the fastener head. During molding, fastener elements are pulled from their mold cavities through cavity portions of the raised bases.

Abstract: A material for covering a surface of a home or building is provided in the form of a flexible laminate having a fastening side comprising a sheet-form fastener component, and an opposite side formed by a sheet of paper laminated to the fastener component to increase the dimensional stability of the fastener component for covering and fastening over a wide area. The fastener component can have either hooks or loops. The laminate is particularly useful for laying flooring with low backlash between adjacent pieces.

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 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: Methods of forming a loop product are provided. Methods include needling polymeric fibers through a substrate to form hook-engageablc loop structures of the fibers extending from one surface of the substrate and then using heat and pressure to 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. Loop products are also provided.

Abstract: Methods of making a sheet-form loop product are provided. One method includes placing a layer of staple fibers against a first side of a substrate comprising a nonwoven web; needling fibers of the layer through the substrate by penetrating the substrate with needles that drag portions of the fibers through the substrate, leaving exposed loops of the fibers extending from a second side of the substrate; and anchoring fibers forming the loops by fusing the fibers to each other and to filaments of the nonwoven web on the first side of the substrate, while substantially preventing fusion of the fibers on the second side of the substrate.

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 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.