Patent Application
20060107501
This invention relates to molded cooperative fasteners, and methods of manufacturing and using the cooperative fasteners.
Cooperative fasteners are useful to provide means of releasably attaching two objects together, or attaching together two portions of a single object. A male fastener, for example a hook carrying fastener, can become engaged with a female touch fastener, for example a loop carrying fastener, simply by the hooks contacting the loops on the female touch fastener. In some instances, the male touch fastener can become inadvertently engaged with other fibrous materials, such as fabrics and human hair, sometimes damaging such materials. Additionally, the exposure of loop carrying fasteners to fibrous material can cause fouling of the fastener, reducing the effectiveness and the life of the fastener.
In general, the invention features fasteners in which the exposure of the male fastener elements is decreased at times when the male fastener element is not intended to be engaged. In some instances touch fasteners that include a foam adjacent the hooks are incorporated into objects, including household and consumer objects. In some instances, the height of the foam is greater than the height of the male fastener elements when the fastener is not engaged with a female touch fastener. To engage the male fastener element, the foam is compressed, thus exposing the male fastener elements to allow engagement with the female fastening elements.
In one aspect, the invention includes a touch fastener, including: a sheet form base having an upper face and a lower face; a plurality of male fastener elements, each fastener element having a stem molded integrally with and extending from the upper face of the sheet form base; and a foam positioned adjacent to the upper face of the sheet form base, the foam extending to a height greater than the height of at least some of the male fastener elements, wherein a portion of the foam is disposed between at least some of the fastener elements.
In some embodiments, the touch fastener includes one or more of the following features. The foam can be foam is disposed between substantially all of the fastener elements. The foam can cover substantially the entire upper face of the sheet form base. The foam can be attached to the upper face of the sheet form base, or can be embedded in the upper face of the sheet form base. The foam can be an open cell foam. The fastener elements can be arranged in longitudinally extending tracts. The fastener elements can have a height of less than about 0.05 inch (1.37 millimeters), for example, a height of between about 0.0005 and 0.05 inch (0.127 and 1.27 millimeters). The fastener elements can be arranged in an array uniformly covering substantially the entire upper face of the sheet form base. The fastener elements can be arranged with a density of at least about 100 fastener elements per square inch (15.5 hooks per centimeter), for example at least about 1000 fastener elements per square inch (155 hooks per centimeter). The fastener elements can include hooks, can be mushroom shaped or palm tree shaped. The foam can include PVC or PU. The foam can be coated with metallic particles. At least a portion of the lower face of the sheet-form base can be coated with metallic particles. At least a portion of the male fastener elements can be embedded with metallic particles. At least a portion of the foam can be embedded with metallic particles. The foam can extend longitudinally beyond the sheet form base. The lower face of the sheet form base can carrie an adhesive material. A non-woven fabric can be mounted on the lower face of the sheet-form base.
In another aspect, the invention includes a touch fastener including; a sheet form base having an upper face and a lower face; a foam positioned adjacent to the upper face of the sheet form base; and array of male fastener elements, each fastener element having a stem molded integrally with and extending from the upper face of the sheet form base, wherein the foam extends longitudinally beyond the sheet form base and wherein a portion of the foam is disposed between at least some of the fastener elements.
In some embodiments, the touch fastener includes one or more of the following features. The foam can be disposed between substantially all of the fastener elements. The touch fastener can include an adhesive on the lower face of the sheet form base. The foam can cover substantially the entire upper face of the sheet form base. The touch fastener can also include a plurality of arrays of male fastener elements arranged in longitudinally extending tracks, wherein the arrays of male fastener elements alternate with longitudinally extending tracks that are substantially free from male fastener elements.
In another aspect, the invention includes a touch fastener including; a sheet form base having an upper face and a lower face; a foam positioned adjacent to the upper face of the sheet form base; and an array of male fastener elements, each fastener element having a stem molded integrally with and extending from the upper face of the sheet form base, wherein a portion of the foam is disposed between at least some of the fastener elements and wherein the foam extends around the array of fastener elements, the foam extending around the array of fastener elements being of a height greater than the height of the fastener elements.
In some embodiments, the touch fastener includes one or more of the following features. The height of the foam disposed between the fastener elements can be greater than the height of the fastener elements. The foam can be disposed between substantially all of the fastener elements. The foam can cover substantially the entire upper face of the sheet form base. The touch fastener can also include an adhesive on the lower face of the sheet form base.
In another aspect, the invention includes a touch fastener including; a sheet form base having and upper face and a lower face; a plurality of male fastener elements, each fastener element having a stem molded integrally with and extending from the upper face of the sheet form base; and a fibrous non-woven material positioned adjacent to the upper face of the sheet form base, wherein a portion of the fibrous non-woven material is disposed between at least some of the fastener elements and wherein the fibrous non-woven material extends longitudinally beyond the sheet form base.
In some embodiments, the touch fastener includes one or more of the following features. The fibrous non-woven material can cover substantially the entire upper face of the sheet form base. The fibrous non-woven material can be disposed between substantially all of the fastener elements. The fibrous non-woven material can be felt.
In another aspect, the invention includes an adjustable cap including; a rim positioned to extend about a wearer's head; and an adjustable fastener arranged to permit adjustment of the rim; the fastener including a female touch fastener; and a male touch fastener configured for releasable engagement with the female touch fastener, and including an array of discrete male fastener elements extending from a common surface to distal ends, and a foam disposed on the common surface and extending across the array of fastener elements; wherein the foam extends from the common surface to beyond the distal ends of at least some of the fastener elements. In some embodiments, foam extends to beyond the distal ends of substantially all of the fastener elements with the foam in an uncompressed state.
In another aspect, the invention includes method of adjusting the size of a cap including; providing a cap including a rim positioned to extend about a wearer's head; and an adjustable fastener arranged to permit adjustment of the rim; the fastener including a female touch fastener; and a male touch fastener configured for releasable engagement with the female touch fastener, and including an array of discrete male fastener elements extending from a common surface to distal ends, and a foam disposed on the common surface and extending across the array of fastener elements; wherein the foam extends from the common surface to beyond the distal ends of at least some of the fastener elements; trying on the cap on a subject, and engaging the male and female touch fasteners. In some embodiments, foam extends to beyond the distal ends of substantially all of the fastener elements with the foam in an uncompressed state.
In another aspect, the invention includes a sealable bag including a body having a first opposing side wall and a second opposing side wall, the first and the second side walls having edges, the edges being joined to form therebetween a pouch having an open end; a closure including first and second elongated fastener strips, wherein the first elongated strip is attached to the first opposing side wall and includes female fastener elements, and wherein the second elongated fastener strip is attached to the second opposing side wall and comprises male fastener elements from a first surface and foam disposed on the first surface wherein at least a portion of the foam is disposed between the male fastener elements and at least a portion of the foam extends to a height greater than the height of the male fastener elements. In some embodiments, the height of the foam is greater than the height of substantially all of the male fastener elements when the foam is not compressed.
In another aspect, the invention includes a closable garment including: a garment having a first portion and a second portion; and a first cooperative fastener for securing the garment on a wearer, the first fastener including a female fastener component on the first portion of the garment, and a second cooperative fastener on the second portion of the garment, arranged for cooperative engagement with the first cooperative fastener; wherein the second cooperative fastener includes male fastener elements and a foam disposed on a first surface, wherein the foam is disposed between at least a portion of the male fastener elements, and wherein the height of at least a portion of the foam is greater than the height of at least some of the male fastener elements. In some embodiments, the height of the foam is greater than the height of substantially all of the male fastener elements when the foam is not compressed.
In another aspect, the invention includes a stackable floor mat including: a mat including a flexible material having and upper surface and a lower surface; and a fastener secured to the lower surface of the mat, the fastener including a sheet form base having an inner face secured to the lower surface of the mat and an outer face, a plurality of male fastener elements disposed on at least a portion of the outer face of the base, and foam disposed on at least the portion of the outer face of the base where the male fastener elements are disposed, wherein the height of the foam is greater than the height of the male fastener elements.
In some embodiments, the stackable floor mat includes one or more of the following features. The height of the foam can be greater than the height of substantially all of the male fastener elements when the foam is not compressed. The material can be a synthetic material. The mat can be a rubber mat. The material can be a natural material. The mat can include a mixture of natural and synthetic material.
In another aspect, the invention includes a door including; an aperture defining an opening sized for a domesticated animal to pass there through; and a door, wherein affixed to a first side of the door and sized to cover the aperture comprises a material having a first surface and a second surface; secured to the first side of the door, is a first cooperative fastener including female fastener elements; and secured to the material and arranged for cooperative engagement with the first cooperative fastener, a male touch fastener including a sheet form base having an inner face secured to the material and an outer face, a plurality of male fastener elements disposed on at least a portion of the outer face, and foam disposed on at least the portion of the outer face of the base and between at least a portion of the male fastener elements, wherein the height of the foam is greater than the height of at least a portion of the male fastener elements. In some embodiments, the height of the foam is greater than the height of substantially all of the male fastener elements when the foam is not compressed.
In another aspect, the invention includes a hair roller including; an elongated central portion including, a first end and a second end, each of which are formed on opposed surfaces of the central portion, and a generally cylindrical shape having a substantially circular shaped cross-section throughout its length; and secured to the central portion, a cooperative fastener including a sheet form base having an inner face secured to the central portion and an outer face, a plurality of male fastener elements disposed on at least a portion of the outer face of the base, and foam disposed on at least the portion of the outer face of the base where the male fastener elements are disposed, wherein the height of the foam is greater than the height of at least a plurality of the male fastener elements.
In some embodiments, the hair roller includes one or more of the following features. The height of the foam can be greater than the height of substantially all of the male fastener elements when the foam is not compressed. The fastener can be positioned to extend along the elongated center portion substantially from the first end to the second end. The hair roller can include a plurality of cooperative fasteners. The surface area of the central portion can be generally a continuous cylinder, the surface area of the central portion can be discontinuous, or the surface area of the central portion can include discontinuous strips of material extending from the first end to the second end of the central portion.
In another aspect, the invention includes a flooring including; a material having an upper and a lower surface; and secured to the lower surface, a cooperative fastener including a sheet form base having an inner face secured to the lower surface of the material and an outer face, a plurality of male fastener elements disposed on at least a portion of the outer face of the base, and foam disposed on at least the portion of the outer face of the base where the male fastener elements are disposed, wherein the height of the foam is greater than the height of a plurality of the male fastener elements.
In some embodiments, the flooring includes one or more of the following features. The height of the foam can be greater than the height of substantially all of the male fastener elements when the foam is not compressed. The material can be a flexible material, a synthetic material, or a natural material. The flooring can be sized to approximate the surface area of a floor of a room.
In another aspect, the invention includes a method of securing a door. The method includes; securing a first cooperative cooperative fastener to a door frame; securing a second cooperative cooperative fastener to a door arranged for cooperative engagement with the first cooperative cooperative fastener, the second cooperative cooperative fastener including a sheet form base having an inner face secured to the door and an outer face, a plurality of male fastener elements disposed on at least a portion of the outer face of the base, and foam disposed on at least the portion of the outer face of the base where the male fastener elements are disposed, wherein the height of the foam is greater than the height of a plurality of the male fastener elements; and closing the door to engage the first and second cooperative cooperative fasteners. In some embodiments, the height of the foam is greater than the height of substantially all of the male fastener elements when the foam is not compressed.
In another aspect, the invention includes a box having; six sides, and secured on one side a cooperative fastener including a sheet form base having an inner face secured to the box and an outer face, a plurality of male fastener elements disposed on at least a portion of the outer face of the base, and foam disposed on at least the portion of the outer face of the base where the male fastener elements are disposed, wherein the height of the foam is greater than the height of a plurality of the male fastener elements.
In some embodiments, the box includes one or more of the following features. The height of the foam can be greater than the height of substantially all of the male fastener elements when the foam is not compressed. The box can be sized to hold 12 cans configured in a 6 by 2 configuration. A plurality of cooperative fasteners can be secured to the box.
In another aspect, the invention includes an absorbent article including a flexible strip including a sheet form base having an inner face and an outer face, a plurality of male fastener elements disposed on at least a portion of the outer face of the flexible strip, and foam disposed on at least the portion of the outer face of the flexible strip where the male fastener elements are disposed, wherein the height of the foam is greater than the height of a plurality of the male fastener elements. The absorbent article can be, for example, a diaper, a feminine hygiene product, a training pant, an incontinence product, or a medical garment.
The touch fasteners described can include one or more of the following benefits. The touch fasteners can be deactivated, so as to not inadvertently become engaged with fibrous materials. The foam may provide a barrier to the male fastener elements that will prevent fouling of the fastener elements, thus providing a longer lasting touch fastener. The foam may also provide an improved hand to the male fastener element, preventing a scratchy or rough feel of the male fastener elements against a user's skin.
The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
Like reference symbols in the various drawings indicate like elements.
The extrusion head 78 supplies a continuous sheet of molten resin 82 to a nip 84 formed between a base roll 80a and a mold roll 80b. As molten resin 82 enters nip 84, a sheet of foam 86 is fed through the nip 84 between the mold roll 80b and the molten resin 82. Due to pressure applied at the nip by rolls 80a and 80b, molten resin 82 is forced through the foam 86 into hook cavities 88, forming the hooks 16 described above. A guide roller 90 is situated diagonally upwardly to assist in the removal of the finished touch fastener 10 from mold roll 80b. A set of upper and lower take-up rollers 92, 94, rotating at a speed slightly higher than the rotating speed of the die wheel 80b, are situated forwardly of the guide roller 90.
The structure of the die wheel 100 is substantially identical with the structure disclosed in U.S. Pat. No. 4,775,310, which is incorporated herein by reference in its entirety. Die wheel 100 defines a multiplicity of hook-element-forming cavities 108 with their bases opening to the circumferential surface of the die wheel. The die wheel 100 is driven to rotate in the direction indicated by the arrow in
A sheet of foam 110 is drawn from a roll and introduced between the upper arcuate surface 98 of the injection die 96 and the circumferential surface of the die wheel 100. A guide roller 112 is situated diagonally upwardly, and a set of upper and lower take-up rollers 114, 116 rotating at a speed slightly higher than the rotating speed of the die wheel 100, are situated forwardly of the guide roller 112.
The foam is compressed as it enters into the nip (as shown in
In some cases, the foam springs back to a thickness that is greater than the height of the fastener elements, causing the fastener elements to be entirely submerged in the foam. Although the fastener elements can be entirely submerged in the foam, loops of appropriate stiffness can be used to push through the foam and engage the hooks as discussed above.
As described above, the resin pierces through the foam to enter mold cavities that form the male fastener elements. Accordingly, the pierce in the foam also provides an opening for the male fastener elements to push through upon engagement with female fastener elements. In some embodiments, aggressive male fastener elements are used to more easily allow engagement of the male fastener elements with female fastener elements. For example male fastener elements of a stiff material or male fastener elements having a sharp edge can more easily push through the foam when the male fastener elements are submerged by the foam. Because in this instance the male fastener elements are submerged in foam when not engaged with female fastener elements, the more aggressive male fastener elements will not negatively impact the feel of the touch fastener, for example on the skin of the user.
In some instances, the hook cavities 88 in the mold roll 80b are positioned to manufacture touch fasteners having fastener elements that do not uniformly cover the sheet form base, but rather are positioned in longitudinally disposed strips.
A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope of the following claims.
