IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
|
출원번호 |
US-0997337
(2004-11-24)
|
등록번호 |
US-7303711
(2007-12-04)
|
발명자
/ 주소 |
- Gallant,Christopher M.
- Shepard,William H.
|
출원인 / 주소 |
|
대리인 / 주소 |
|
인용정보 |
피인용 횟수 :
11 인용 특허 :
57 |
초록
▼
A rotating mold roll defines an array of molding cavities. The mold roll is positioned adjacent a pressure device to define a pressure nip. At least one of the mold roll and the pressure device define a molding recess that is larger than the molding cavities. Resin is introduced to the rotating mol
A rotating mold roll defines an array of molding cavities. The mold roll is positioned adjacent a pressure device to define a pressure nip. At least one of the mold roll and the pressure device define a molding recess that is larger than the molding cavities. Resin is introduced to the rotating mold roll and pressed into the molding cavities and the molding recess to form discrete projections and a series of discrete, longitudinally spaced apart structural features. The projections and structural features are carried on a continuous sheet-form base. The resin is removed from the mold roll to expose a continuous preform sheet including the base, the projections, and the structural features. The structural features are arranged along the preform sheet in a longitudinally repeating pattern. The preform sheet is separated into multiple discrete products including an array of the projections and at least one of the structural features.
대표청구항
▼
What is claimed is: 1. A method of making discrete fastener products, the method comprising: providing a rotating mold roll having a peripheral surface, the mold roll defining an array of molding cavities extending inwardly from the peripheral surface, the mold roll being positioned adjacent a pres
What is claimed is: 1. A method of making discrete fastener products, the method comprising: providing a rotating mold roll having a peripheral surface, the mold roll defining an array of molding cavities extending inwardly from the peripheral surface, the mold roll being positioned adjacent a pressure device to define a pressure nip, at least one of the mold roll and the pressure device defining at least one molding recess substantially larger than the molding cavities; introducing resin to the rotating mold roll; pressing the resin into the molding cavities to form a multiplicity of discrete projections, and pressing the resin into the molding recess to form a series of discrete, longitudinally spaced apart structural features, the projections and the structural features being carried on a continuous sheet-form base; removing the resin from the mold roll to expose a continuous preform sheet comprising the base, the projections, and the structural features, the structural features being arranged along the preform sheet in a longitudinally repeating pattern; and separating the preform sheet into multiple discrete products, each discrete product including an array of the projections and at least one of the structural features. 2. The method of claim 1, wherein the molding cavities are shaped to form projections with heads overhanging the base. 3. The method of claim 1, wherein the pressure device is a counter-rotating pressure roll. 4. The method o claim 3, wherein the pressure roll defines the molding recess. 5. The method of claim 1, wherein the molding recess comprises a groove. 6. The method of claim 5, wherein the groove includes a bottom surface, and multiple protrusions extend from the bottom surface. 7. The method of claim 6, wherein the protrusions are circumferentially spaced apart. 8. The method of claim 1, wherein the molding recess comprises a central protrusion. 9. The method of claim 1, wherein the molding recess comprises multiple discrete depressions arranged in a predetermined configuration. 10. The method of claim 1, wherein the molding recess is defined by the mold roll. 11. The method of claim 10, wherein the molding recess comprises a continuous groove defined by the peripheral surface of the mold roll. 12. The method of claim 10, wherein the mold roll includes an outer edge region, the molding recess extending circumferentially along the outer edge region. 13. The method of claim 10, wherein multiple molding recesses extend across a transverse direction of the mold roll. 14. The method of claim 1, wherein the molding recess is defined by an insert, the insert being retained within at least one of the mold roll and the pressure device. 15. The method of claim 14, wherein the insert is retained within the mold roll. 16. The method of claim 15, wherein the insert extends transversely from a first side of the mold roll to a second side of the mold roll. 17. The method of claim 14, wherein the insert defines multiple molding recesses. 18. The method of claim 1, wherein the resin is continuously introduced to the mold roll. 19. The method of claim 18, wherein the resin is introduced in discrete lanes separated along a transverse direction of the mold roll. 20. The method of claim 1, wherein introducing resin to the mold roll comprises extruding the resin into the pressure nip. 21. The method of claim 1, wherein introducing resin to the mold roll comprises extruding the resin onto a sheet-form material and continuously introducing the sheet-form material and the resin into the pressure nip. 22. The method of claim 21, wherein the resin is extruded onto the sheet-form-material in lanes separated along a transverse direction of the sheet-form material. 23. The method of claim 1, wherein the projections as formed include a stem portion and a head portion, the head portion overlying the base. 24. The method of claim 23, wherein the projections have distal ends extending downward toward the base. 25. The method of claim 1, wherein each projection comprises a wedge with an upper surface extending from the base at an angle of between about 5 degrees and 45 degrees and terminating in a raised distal edge. 26. The method of claim 25, wherein the raised distal edge extends from the base at an angle between about 45 degrees and 90 degrees. 27. The method of claim 25, wherein the wedges are arranged in a single row along the base. 28. The method of claim 25, wherein the discrete product includes an elongated strap having a free end. 29. The method of claim 28, wherein each structural feature forms a hole sized to receive the free end of the strap. 30. The method of claim 29, wherein the structural features comprise surfaces configured to engage the wedges when the free end of the strap is pulled through the hole. 31. The method of claim 29, wherein the structural feature is arranged at an end of the strap opposite the free end. 32. The method of claim 1, wherein the structural features comprise surfaces defining holes extending into the sheet-form base. 33. The method of claim 32, wherein the holes extend completely through the sheet-form base. 34. The method of claim 32, wherein the holes are defined by a region of the base that is substantially thicker than the region of the base carrying the projections. 35. The method of claim 34, wherein the discrete product includes an elongated strap having a free end and each structural feature forms a hole sized to receive the free end of the strap. 36. The method of claim 35, wherein the structural features comprise surfaces configured to engage the projections when the free end of the strap is pulled through the hole. 37. The method of claim 1, wherein the structural features comprise resin surfaces extending outwardly from the base. 38. The method of claim 37, wherein the structural features form resilient fingers arranged in associated sets defining a boss sized to be received in a media disc-mounting hole. 39. The method of claim 1, further comprising introducing a longitudinally continuous backing material to the mold roll along with the resin. 40. The method of claim 39, wherein the resin is introduced in discrete regions interconnected by the backing material. 41. The method of claim 40, wherein the discrete regions of resin comprise longitudinal bands. 42. The method of claim 39, wherein the backing material is laminated to the resin under nip pressure. 43. The method of claim 42, wherein the backing material comprises a non-woven knit. 44. The method of claim 42, wherein the backing material comprises a foam material. 45. The method of claim 42, wherein the backing material comprises a metallized film. 46. The method of claim 42, wherein the backing material includes fibers capable of engaging the projections when the product is folded upon itself. 47. The method of claim 1, wherein the continuous pre-form sheet includes a continuous resin layer. 48. The method of claim 1, wherein separating the fastener sheet comprises cutting the sheet. 49. The method of claim 48, wherein the sheet is conveyed through a cutter, the cutter being controlled to intermittently cut the sheet as the sheet is conveyed. 50. The method of claim 49, wherein the cutter comprises a roll having cutting blades configured to perforate the sheet in predetermined regions. 51. The method of claim 1, further comprising weakening the sheet to define boundaries along which the sheet will be separated. 52. The method of claim 51, wherein weakening the sheet comprises perforating the sheet in predetermined regions. 53. The method of claim 52, wherein perforating the sheet comprises conveying the sheet between a cutting roll and a support roll, the cutting roll having protrusions extending from a peripheral surface. 54. The method of claim 1, further comprising introducing a loop material into the nip, the loop material being capable of engaging the projections when the product is folded upon itself. 55. The method of claim 54 wherein the loop material is introduced into a central region of the nip. 56. The method of claim 1, further comprising pressing the resin into a second molding recess defined by at least one of the mold roll and the pressure device to form a second structural feature carried by the sheet-form base. 57. The method of claim 56, wherein the second molding recess comprises multiple depressions arranged in a predetermined configuration. 58. The method of claim 57, wherein the multiple depressions are arranged to form ribs. 59. The method of claim 58, wherein the ribs extend longitudinally on the sheet-form base. 60. The method of claim 56, wherein the second molding recess is defined by the mold roll. 61. The method of claim 56, wherein the second molding recess comprises multiple circumferential channels defined by the mold roll to form longitudinally extending ribs. 62. The method of claim 56, wherein the second structural feature has a thickness at least as great as a thickness of the structural features. 63. A method of making discrete fastener products, the method comprising: providing a rotating mold roll having a peripheral surface, the mold roll defining an array of molding cavities extending inwardly from the peripheral surface, the mold roll being positioned adjacent a pressure device to define a pressure nip; introducing resin to the rotating mold roll; pressing the resin into the molding cavities to form a multiplicity of discrete projections, the projections being carried on a continuous sheet-form base; removing the resin from the mold roll to expose a continuous preform sheet carrying the projections; creating multiple, longitudinally separated slots within the preform sheet; and separating the preform sheet into multiple discrete products, each discrete product including an array of the projections and at least one of the slots.
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