Velcro Industries B.v.

J Scott Neumann

Andrew Cecil Harvey

Stephen C Jens

Richard M Formato

Howard A Kingsford

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. In some other cases it includes a belt. Various control schemes are also disclosed, as are means to provide cooling. In some particularly useful embodiments, at least one of the rolls of the apparatus has a resiliently deformable surface. Methods of molding fastener elements directly on a sheet material, such as sandpaper, are also disclosed, as well as methods for laminating.

Continuous molding of fastener products and the like and products produced thereby

A fastener member ( ) useful for separable engagement with surface fibers of a low-loft, non-woven fabric, or the like, has a base web ( ) and a multitude of fastener elements ( ) formed with and extending from the base web ( ). The fastener elements have a profile that comprises an elongated stem portion ( ) adjacent the base web ( ) and including at an acute angle to the base. A crook portion ( ) 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 ( ). The acute angle of the stem of the elements ( ) enables them to flex toward the base. Offset pair of such elements ( ) can operatively move in a pincer-type motion to engage fibers ( ) 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.

Continuous molding of fastener products using a pressure roll having a resilient surface

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.

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Natick, MA, United States of America

J Scott Neumann