Hook and loop fastening structures may be used in various applications to secure objects adjacent each other. For example, hook fastening strips may be molded onto a surface of a foam bun of an automobile seat, and loop material may be provided on an inner surface of an automobile seat covering to engage the hook fastening strips and secure the seat covering to the foam bun. Flexible hook fastening strips may be utilized adjacent portions of the foam bun having contours, and straight hook fastening strips may be utilized on straight portions of the foam bun, such as longitudinally down the center of the bun.
Prior art flexible hook fastener strip such as the fastener strips 21 shown in FIGS. 1 and 2A-2D are die cut into the shape of the trench 12, which limits the fastener strips to use only with trenches having that particular shape. In addition, a covering 23 is disposed over the hooks to prevent foam from seeping between the hooks. However, an operator has to remove this covering 23 from a base 24 on which the hooks are disposed after removing the formed foam bun from the mold 10, which results in an extra manufacturing step for the operator and wasted material for the manufacturer. Furthermore, as shown in
Straight fastener strips 22, such as those disclosed in U.S. Published Patent Application Number 2007/0240289 and shown in
Thus, a need in the art exists for an improved flexible fastener strip that provides a balance of flexibility and stiffness for easier maneuverability by an operator and increased efficiency in the manufacturing process.
Various embodiments of the invention provide an elongated, flexible fastener strip assembly comprising two or more hook fastener elements and an elongated connecting member. Each of the hook fastener elements has: (1) an elongated base having an upper surface, a lower surface opposite the upper surface, a first end, a second end opposite the first end, and a longitudinal axis that extends between the first end and the second end; and (2) a plurality of hooks that extend upwardly from the upper surface. Each of the hook fastener elements defines at least one elongated hole that extends through the upper and lower surfaces.
The elongated connecting member comprises a spine and at least two protrusions. The spine has a width dimension in a width plane and a thickness dimension in a thickness plane, and the width dimension is larger than the thickness dimension. The protrusions extend from a first side of the spine in the width plane. The first protrusion is adapted for securely engaging the at least one elongated hole of a first hook fastener element, and the second protrusion is adapted for securely engaging the at least one elongated hole of a second hook fastener element such that the first end of the first hook fastener element is disposed adjacent the first end of the second hook fastener element, the spine is disposed adjacent the lower surfaces of the hook fastener elements, and the width plane is substantially perpendicular to the lower surface of the hook fastener elements. The elongated fastener strip assembly according to this embodiment exhibits flexibility in the thickness plane of the elongated connecting member and stiffness in the width plane of the elongated connecting member.
In a further embodiment, the first hook fastener element further defines a first elongated slit that extends along the longitudinal axis of the first hook fastener element from the first end to a point adjacent an elongated hole adjacent the first end. In addition, the second hook fastener element further defines a second elongated slit that extends along the longitudinal axis of the second hook fastener element from the first end to a point adjacent an elongated hole adjacent the first end. Furthermore, the elongated connecting member further comprises a stabilizing member disposed intermediate the first protrusion and the second protrusion. The stabilizing member extends from the first side of the spine in the width plane and has a thickness substantially equal to the spine and the first and second protrusions. The stabilizing member is adapted for engaging the first elongated slit and the second elongated slit when the first hook fastener element is secured in an end-to-end relationship with the second hook fastener element.
In a further embodiment, the elongated flexible fastener strip assembly comprises a third hook fastener element, and the elongated connecting member comprises a third and fourth protrusion extending from the first side of the spine. The third and fourth protrusions are adapted for engaging the elongated hole defined in the third hook fastener element and a second elongated hole defined in the second hook fastener element such that the second ends of the third hook fastener element and the second hook fastener element are disposed adjacent each other in an end-to-end relationship.
In an alternative embodiment, an elongated, flexible fastener strip assembly comprises a straight hook fastener element and an elongated connecting member. The straight hook fastener element comprises an elongated base having an upper surface, a lower surface opposite the upper surface, a first end, a second end opposite the first end, and a longitudinal axis extending between the first end and the second end. The straight hook fastener element also includes a plurality of hooks extending upwardly from the upper surface and at least one narrow portion that extends between two wide portions of the base. The wide portions are able to bend relative to each other through the narrow portion, and each of the wide portions of the hook fastener element further defines at least one elongated hole extending through the upper and lower surfaces. The elongated connecting member comprises a spine and at least two protrusions. The spine has a width dimension in a width plane and a thickness dimension in a thickness plane, wherein the width dimension is larger than the thickness dimension, and the at least two protrusions extend from a first side of the spine in the width plane. The first protrusion is adapted for securely engaging the at least one elongated hole of a first wide portion of the hook fastener element and the second protrusion is adapted for securely engaging the at least one elongated hole of a second wide portion of the hook fastener element such that the spine is disposed adjacent the lower surface of the hook fastener element, and the width plane is substantially perpendicular to the lower surface of the hook fastener element. The elongated fastener strip assembly exhibits flexibility in the thickness plane of the elongated connecting member and stiffness in the width plane of the elongated connecting member.
Various other embodiments of the invention provide a method of assembling a plurality of hook fastener elements in an end-to-end relationship with a connecting member. The method includes the steps of: (1) providing two or more hook fastener elements that each have: (a) an elongated base having an upper surface, a lower surface opposite the upper surface, a first end, a second end opposite the first end, and a longitudinal axis extending between the first end and the second end; and (b) a plurality of hooks extending upwardly from the upper surface, wherein each of the hook fastener elements defines at least one elongated hole extending through the upper and lower surfaces; (2) providing an elongated connecting member comprising a spine and at least two protrusions, the spine having a width dimension in a width plane and a thickness dimension in a thickness plane, the width dimension being larger than the thickness dimension, and the protrusions extending from a first side of the spine in the width plane; (3) securely engaging the first protrusion in the at least one elongated hole of a first hook fastener element; and (4) securely engaging the second protrusion in the at least one elongated hole of a second hook fastener element. By securely engaging the first protrusion in the elongated hole of the first hook fastener element and engaging the second protrusion in the elongated hole of the second hook fastener element, the first end of the first hook fastener element is disposed adjacent the first end of the second hook fastener element, the spine is disposed adjacent the lower surfaces of the hook fastener elements, and the width plane of the elongated connecting member is substantially perpendicular to the lower surface of the hook fastener elements.
Having thus described various embodiments of the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
Various embodiments of the invention are described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown in the figures. Indeed, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements.
Various embodiments of the invention provide an elongated flexible fastener strip assembly that includes two or more hook fastener elements and an elongated connecting member for joining the hook fastener elements in an end-to-end relationship. In particular, in various embodiments, the elongated flexible fastener strip assembly includes two or more hook fastener elements and an elongated connecting member. Each of the two or more hook fastener elements include a plurality of hooks that extend upwardly from an upper surface of the hook fastener elements and define at least one elongated hole extending through the upper surface and a lower surface of the hook fastener element. The elongated connecting member includes a spine and two or more protrusions extending from one side of the spine in a width plane, and a width dimension of the elongated connecting member in the width plane is greater than a thickness dimension of the elongated connecting member in a thickness plane that is perpendicular to the width plane. The protrusions are adapted for engaging each of the elongated holes of the hook fastener elements. When the protrusions are engaged with the holes of the hook fastener elements, the spine is disposed along the lower surface of the hook fastener elements. The assembly according to various embodiments exhibits an improved level of stiffness and flexibility in the thickness plane of the elongated connecting member, which is parallel to the upper and lower surfaces of each hook fastener element, and in the width plane of the elongated connecting member. More detailed descriptions of various embodiments of the hook fastener elements and the elongated connecting member of the elongated flexible fastener strip assembly are provided below.
In a further embodiment, a width of an end portion 44 of at least the first end 35 of each hook fastener element 31 begins to decrease along the longitudinal axis 37 toward the first end 35, forming an arrow-shape. This arrangement allows for the ends of two adjacent hook fastener elements 31 assembled in an end-to-end relationship to move at an angle to each other in a width plane of the hook fastener elements 31.
In addition, according to one embodiment, the hook fastener element 31 also defines at least one elongated slit 42 that extends along the longitudinal axis 37 from the first end 35 to a point adjacent the elongated hole 41 adjacent the first end 35.
In another embodiment in which the hook fastener element 31 is to be joined between two other hook fastener elements 31 in an end-to-end relationship, the hook fastener element 31 further defines a second elongated hole 41 adjacent the second end 36 of the hook fastener element 31. In addition, the hook fastener element 31 may further define a second elongated slit 42 that extends along the longitudinal axis 37 from the second end 36 to a point adjacent the elongated hole 41 adjacent the second end 36.
According to various embodiments, the hook fastener element 31 is formed of a plastic material (e.g., polyamides, polyurethanes, polyesters, or polybutylene terephthalate (PBT)), and the base 32, hooks 38, and longitudinal side walls 39a, 39b are integrally formed during a molding process. In a particular embodiment, the strip 31 further includes a monofilament (e.g., iron monofilament) extending longitudinally through the base 32 that has magnetic properties. This monofilament attracts, aligns, and holds the hook fastener element 31 adjacent a magnetic trench, such as the magnetic trench 12 described above in relation to
According to a particular embodiment, the hook fastener elements 31 are manufactured from straight hook fastener elements such as the straight hook fastener elements described in U.S. Published Patent Application Number 2007/0240289, which is herein incorporated by reference in its entirety. In particular, straight hook fastener elements are die-cut into smaller straight hook fastener elements 31, and the process further includes cutting the elongated holes 41 and the ends 35, 36 of the hook fastener elements 31 into the arrow-shape described above. In other alternative embodiments, the cutting may be done using a laser cutting device or by grinding.
The length of the hook fastener elements, the location of the elongated holes relative to the ends of the hook fastener elements, and whether an elongated slit 42 is provided adjacent the ends of the hook fastener elements may be a function of the radius of the contour for which the elongated flexible fastener strip assembly will be used. For example, the length of the hook fastener elements 31 in the above described embodiments is longer than the length of the hook fastener elements 71 described below in relation to the embodiments shown in
In a particular embodiment, the elongated connecting member 50 further includes a stabilizing member 57 that extends in the width plane from the same side of the spine 51 as the protrusions 52 and is disposed intermediate the protrusions 52. The stabilizing member 57 has a thickness and width substantially equal to the thickness and width, respectively, of the two protrusions 52. In the embodiment shown in
According to various embodiments, the elongated connecting member 50 is formed of a plastic material (e.g., polyester, PVC, HDPE, or nylon), and the spine 51, protrusions 52, and stabilizing member 57 are integrally formed. In a particular embodiment, the spine 51, protrusions 52, and stabilizing member 55 are formed by die-cutting an extruded piece of plastic material using a roller assembly, such as the roller assembly 100 shown in
According to one embodiment, the length of the elongated connecting member may depend on the number of hook fastener elements to be included in the elongated flexible fastener strip assembly and the end use of the elongated flexible fastener strip assembly. For example, the elongated connecting member may be cut to a length substantially equal to the total length of the hook fastener elements to be included in the elongated flexible fastener strip assembly, which is partially shown in
In an alternative embodiment (not shown), the elongated connecting member may be glued to the lower surfaces of the hook fastener elements to prevent separation of the hook fastener elements and the elongated connecting member. In one such embodiment, the protrusions do not include an engaging portion for engaging the upper surface of the hook fastener elements.
According to various embodiments, the flexible fastener strip assemblies 30, 80 described above are sufficiently flexible in the thickness plane of the elongated connecting members 50, 60 to be used along a curved contour, such as discussed above in relation to
Although this invention has been described in specific detail with reference to the disclosed embodiments, it will be understood that many variations and modifications may be effected within the spirit and scope of the invention as described in the appended claims.