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 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.
대표청구항▼
What is claimed is: 1. A method of forming a loop-engaging touch fastener product, the method comprising: providing a preform product formed of thermoformable material and having a sheet-form base and an array of preform stems integrally molded with and extending from the sheet-form base, each of t
What is claimed is: 1. A method of forming a loop-engaging touch fastener product, the method comprising: providing a preform product formed of thermoformable material and having a sheet-form base and an array of preform stems integrally molded with and extending from the sheet-form base, each of the stems including a first portion joined to the base and a second portion extending from the first portion to a terminal end, an intersection of the first and second portions defining a discrete reduction in transverse cross-sectional area of the stem, measured parallel to the sheet-form base, from the first portion to the second portion, an exposed top surface of the first portion defining a shoulder; and deforming at least some of the second portions toward the shoulder to form engaging heads configured to releasably engage a mating loop product. 2. The method of claim 1, wherein the discrete reduction in transverse cross-sectional area occurs at a distance from a top surface of the sheet-form base of at least halfway to the terminal end of the stem. 3. The method of claim 1, wherein a cross-sectional area taken parallel to the sheet-form base near the terminal end of the second portion is less than 50% of any cross-sectional area of the first portion, also taken parallel to the sheet-form base. 4. The method of claim 3, wherein the cross-sectional area taken near the terminal end of the second portion is less than 25% of any cross-sectional area of the first portion. 5. The method of claim 1, wherein each second portion projects above each first portion without overhanging the sheet-form base. 6. The method of claim 1, wherein each first portion is substantially rectangular in shape in transverse cross-section. 7. The method of claim 1, wherein each second portion is substantially rectangular in shape in transverse cross-section. 8. The method of claim 1, wherein each second portion is substantially circular in shape in transverse cross-section. 9. The method of claim 1, wherein each first portion is substantially cruciform in shape in transverse cross-section. 10. The method of claim 1, wherein each second portion defines a pyramid shape, the intersection of the first and second portions defining a base of the pyramid. 11. The method of claim 1, wherein each of the first and second portions have differently shaped transverse cross-sections. 12. The method of claim 1, wherein each first portion is cruciform in shape in transverse cross-section and each second portion is rectangular in shape in transverse cross-section. 13. The method of claim 1, wherein the deforming step includes heating the terminal ends of the second portions with a non-contact heat source. 14. The method of claim 1, wherein the deforming step includes heating the terminal ends of the second portions with a non-contact heat source, and then contacting the terminal ends with a contact surface. 15. The method of claim 14, wherein the contact surface is maintained at a temperature less than room temperature. 16. The method of claim 13, wherein the non-contact heat source is positioned about 0.1 mm to about 30 mm from the terminal ends of the second portions. 17. The method of claim 13, wherein the non-contact heat source is a flame heater. 18. The method of claim 13, wherein the non-contact heat source is a radiant heat source. 19. The method of claim 1, wherein the deforming step includes heating the terminal end of the second portions by contacting the terminal ends with an ultrasonic horn. 20. The method of claim 1, wherein each head has an overhang aspect ratio, defined as an overall length of a chord extending fully across the head, in top view in a machine direction, directly above a nominal lateral-most extent of the stem, divided by a maximum lateral extent of the head in a cross-machine direction beyond the stem, of less than 4.0. 21. The method of claim 20, wherein the overhang aspect ratio is less than 2.5. 22. The method of claim 21, wherein the overhang aspect ratio is less than 2.0. 23. The method of claim 20, wherein each head has a vertical head thickness, measured perpendicular to the sheet-form base from the top surface of the head to a lower surface of the head, of not more than about 0.015 inch.
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