Method and apparatus for producing hook fasteners

Cross-reference of related applications This application claims the interests of US Patent Provisional Application No. 61 / 145,883 filed on January 20, 2009.

The present disclosure relates generally to mechanical fasteners such as hook-and-loop fasteners or touch fasteners, and more specifically to methods and devices for making "hook" fasteners utilizing vibrational energy.

Touch fasteners (commercially known as Velcro®, Scotchmate®, Tri-Hook®, etc.) were originally manufactured using textile technology. Two of the most common types of touch fasteners are hook and loop fasteners and mushroom and loop fasteners.

Hook and loop type fasteners can consist of a pair of textile strips. These textile strips can be combined to form a reusable closure, and one of the combined pair of textile strips is a textile fabric strip with many monofilament elements, like a hook. A textile strip with a multifilament element woven as a loop-shaped protrusion on one surface, with a unique shape protruding from one surface. When the connecting surfaces of these strips are pressed against each other, many hook-shaped elements on one strip entangle the loop elements with the opposing strips, creating a temporary, reusable bond. Once the strip is peeled off, the hook element can be modified and separated from the loop element, allowing the fastener to be used over and over again.

For mushroom-and-loop fasteners, hook-type binding strips are replaced with strips that contain many monofilament protrusions with mushroom-shaped or blunted heads. Mushroom-shaped heads can be formed by heating the tips of straight monofilament protrusions until a flat "mushroom head" is formed on each protrusion. When this strip is pressed against a strip with loop-shaped protrusions on the surface, the mushroomhead can entangle the loop elements with the opposing strips to create a temporary, reusable bond. Once the strip is peeled off, the mushroom-shaped elements can occasionally distort and release the loop elements. Also, two strips, each with mushroom-shaped protrusions, can be engaged by a blunted head that interacts to form a mechanical bond.

Recently, the use of thermoplastic extrusion / molding methods for making touch fasteners has become widespread. In the case of hook-and-loop fasteners, the hook strips are formed by extruding the polymer into a web-like shape with integral protrusions, while the loop strips are also made using woven, knitted or non-woven techniques. Can be manufactured. In the case of mushroom and loop fasteners, the mushroom strip can be manufactured by extruding the polymer into a web-like shape with integrated pin-like protrusions and forming a mushroom-like head over the pin-like protrusions.

The use of extrusion / molding techniques to produce hook-type and mushroom-type touch fasteners reduces manufacturing costs, improves the performance and aesthetics of touch fasteners, and therefore in numerous applications such as tab closures on disposable diapers. Their use is possible.

Examples of techniques used to manufacture extruded / molded type touch fasteners include:

Extrusion / molding of hook fasteners with an integral base, the base may be molded on molding rollers and the hook elements may be molded in individual cavities. The mold can be opened and closed continuously as it rotates to allow the hook to be pulled out. (See, for example, Menzin's US Pat. Nos. 3,762,000, 3,758,657, and Erb's US Pat. Nos. 3,752,619 and Erb's US Pat. No. 3,196,490.)

Extrusion / molding of hook fasteners with an integral base, hook elements may be molded into individual cavities and the mold remains closed. The hook can be pulled out of the cavity after cooling. Therefore, the outer shape of the hook can be somewhat limited as it must be able to be pulled out of the closed mold. (See, for example, Rochlis U.S. Pat. Nos. 3,312,583 and 3,541,216, Fischer U.S. Pat. Nos. 4,775,310 and 4,794,028, and Murasaki U.S. Pat. No. 5,393,475.)

Extrusion of a material web with a series of rails with a hook-like cross section that runs parallel along the top surface of the web. The rail may be intermittently cross-cut to the base material. The base material can be expanded and contracted to ensure a gap between the hook elements. (See, for example, Erb's U.S. Pat. Nos. 3,665,504 and 3,735,468.)

Extrusion of a web of material with a series of molded pins or similar elements, and post-formation of the elements into hook-type or mushroom-type fasteners. (See, for example, U.S. Pat. Nos. 3,182,589, 3,270,408, 5,607,635, 5,755,015, 5,781,969, and 5,792,408.)

One theme common to all of these methods is the melting and feeding of thermoplastics by extruders or similar devices. Although often considered an efficient way to manufacture touch fasteners, extrusion / molding technology typically invests heavily in capital equipment (extruders, coolers, pumping systems, dryers, pellet transport systems). Requires significant processing energy consumption, raw material handling and pre-drying, proper disposal of purge / cleaning materials and starting materials, ventilation of harmful gases, etc., as well as the ability to roll or otherwise process the finished product without interruption. You may need the ability to do it.

<p num="0014"><patcit num="1"><text>U.S. Pat. No. 3,762,000</text></patcit><patcit num="2"><text>U.S. Pat. No. 3,758,657</text></patcit><patcit num="3"><text>U.S. Pat. No. 3,752,619</text></patcit><patcit num="4"><text>U.S. Pat. No. 3,196,490</text></patcit><patcit num="5"><text>U.S. Pat. No. 3,312,583</text></patcit><patcit num="6"><text>U.S. Pat. No. 3,541,216</text></patcit><patcit num="7"><text>U.S. Pat. No. 4,775,310</text></patcit><patcit num="8"><text>U.S. Pat. No. 4,794,028</text></patcit><patcit num="9"><text>U.S. Pat. No. 5,393,475</text></patcit><patcit num="10"><text>U.S. Pat. No. 3,665,504</text></patcit><patcit num="11"><text>U.S. Pat. No. 3,735,468</text></patcit><patcit num="12"><text>U.S. Pat. No. 3,182,589</text></patcit><patcit num="13"><text>U.S. Pat. No. 3,270,408</text></patcit><patcit num="14"><text>U.S. Pat. No. 5,607,635</text></patcit><patcit num="15"><text>U.S. Pat. No. 5,755,015</text></patcit><patcit num="16"><text>U.S. Pat. No. 5,781,969</text></patcit><patcit num="17"><text>U.S. Pat. No. 5,792,408</text></patcit></p>

<p num="0015"> There is a need for methods and equipment to prepare hook-type fastener elements for use in closure systems, especially in reusable closure systems, without the significant capital investment and material inefficiencies described above. Exists.</p>

<p num="0016"> In one exemplary embodiment, the present disclosure describes a method of forming protrusions on a substrate, the method comprising providing a mold having an outer surface and providing a substrate material having a surface. One or both of the mold and the device has a plurality of cavities, the cavities having a shape, including the step of providing the device as a vibration energy source. Then, after this, a step of positioning the substrate material between the mold and the device and a step of energizing the device, in which a part of the substrate material enters the cavity inside the mold surface of the mold and the surface of the substrate material A step of forming a protrusion on at least a portion of the can be followed, the cavity being shaped to form a protrusion, the protrusion being a hook, mushroom, straight pin, angled pin, Formed as one or more of tapered pins, curved pins, hook hooks, multiple limbs, crosses, Y-shapes, and polylobes, each of which is circular, oval, square, rectangular, trapezium. Has solid, hollow and combined cross sections thereof.</p><p num="0017"> In another exemplary embodiment, the present disclosure is a method of forming protrusions on a substrate, a step of providing a substrate material having a surface and a step of providing a device as a vibration energy source, the device. The present invention relates to a method including a step having a surface having a plurality of cavities, the cavities being arranged along at least a part of the surface, and the cavities having a shape. This is then followed by a step of pressing the device against the surface of the substrate material and a step of energizing the device and pushing a portion of the substrate material into a cavity within the surface of the device to form protrusions on the surface of the substrate material. The protrusions can be followed by steps that match the shape of the cavity as a whole, each of which is circular, oval, square, rectangular, trapezium, solid, hollow and combinations thereof. One or more of hooks, mushrooms, straight pins, angled pins, tapered pins, curved pins, hook hooks, multiple limbs, crosses, Y-shapes, and multiple leaves with a cross section of Cavities are formed to form protrusions.</p><p num="0018"> In another exemplary embodiment, the present disclosure relates to a device for forming protrusions on a substrate, the device comprising a mold having a surface and a device as a vibration energy source. One or both of the mold and the device can have multiple cavities, the cavities having a shape, which shape is a loop element or a complementary shape of protrusions or foams, screens or other non-woven materials. Achieves the formation of protrusions that may be post-processed or may be post-processed into a shape suitable for mechanical engagement with the bonding material.</p><p num="0019"> In another exemplary embodiment, the present disclosure relates to a device for forming protrusions on a substrate, the device comprising a device as a vibration energy source, the device having multiple cavities, and the cavities having a shape. The shape, however, provides in the substrate the formation of protrusions that may or may not be post-processed into a shape suitable for mechanical engagement with loop elements or complementary shaped protrusions or other bonding materials.</p><p num="0020"> The present disclosure also relates to an article for mechanical engagement, wherein the article comprises a substrate having two sides and including one or more protrusions extending from one or both sides, the substrate being longitudinal. Having a direction (MD) and a lateral direction (CD), the article has one or more of the following features: i. The substrate has a tensile strength TS1 in the vertical direction, and one or more protrusions have a tensile strength TS2, where TS2 is 50% or more of the value of TS1. ii. The substrate has a shrinkage amount S1 in a given direction, and one or more protrusions have a shrinkage amount S2 in the same direction, and S2 0.50 (S1).</p><p num="0021"> The present disclosure also relates to an article for mechanical engagement, wherein the article comprises a substrate having two sides and including a plurality of protrusions extending from one or both sides, the substrate being within the surface of the substrate. Before forming the protrusions, it has vertical (MD) and horizontal (CD), and the substrate exhibits shrinkage values in which the vertical and horizontal shrinkage is within +/- 20% of each other. It is characterized by having a biaxial orientation, and the substrate exhibits a shrinkage value in which the amount of shrinkage in the vertical and horizontal directions is within the range of +/- 20% of each other after forming protrusions on the surface of the substrate. Has axial orientation.</p><p num="0022"> The accompanying drawings, which are incorporated herein by reference and constitute a portion thereof, serve to illustrate embodiments of the invention and, along with description thereof, explain the principles of the invention.</p>

<figref num="1">FIG. 6 is a schematic cross-sectional side view of a device and method for forming a protrusion that can be used as a hook type fastener in accordance with the present disclosure.</figref><figref num="2">It is a schematic diagram of an exemplary upright shape that can be used as a protrusion according to the present disclosure.</figref><figref num="2A">It is a schematic diagram of an exemplary upright shape that can be used as a protrusion according to the present disclosure.</figref><figref num="2B">It is a schematic diagram of an exemplary upright shape that can be used as a protrusion according to the present disclosure.</figref><figref num="2C">It is a schematic diagram of an exemplary upright shape that can be used as a protrusion according to the present disclosure.</figref><figref num="2D">It is a schematic diagram of an exemplary upright shape that can be used as a protrusion according to the present disclosure.</figref><figref num="2E">It is a schematic diagram of an exemplary upright shape that can be used as a protrusion according to the present disclosure.</figref><figref num="2F">It is a schematic diagram of an exemplary upright shape that can be used as a protrusion according to the present disclosure.</figref><figref num="2G">It is a schematic diagram of an exemplary upright shape that can be used as a protrusion according to the present disclosure.</figref><figref num="2H">It is a schematic diagram of an exemplary upright shape that can be used as a protrusion according to the present disclosure.</figref><figref num="2I">It is a schematic diagram of an exemplary upright shape that can be used as a protrusion according to the present disclosure.</figref><figref num="2J">It is a schematic diagram of an exemplary upright shape that can be used as a protrusion according to the present disclosure.</figref><figref num="2K">It is a schematic diagram of an exemplary upright shape that can be used as a protrusion according to the present disclosure.</figref><figref num="2L">It is a schematic diagram of an exemplary upright shape that can be used as a protrusion according to the present disclosure.</figref><figref num="2M">It is a schematic diagram of an exemplary upright shape that can be used as a protrusion according to the present disclosure.</figref><figref num="2N">It is a schematic diagram of an exemplary upright shape that can be used as a protrusion according to the present disclosure.</figref><figref num="3">FIG. 6 is a schematic cross-sectional side view of another device and method of making a protrusion that can be used as a hook fastener in accordance with the present disclosure.</figref><figref num="4">FIG. 6 is a schematic cross-sectional side view of another device and method of making a protrusion that can be used as a hook fastener in accordance with the present disclosure.</figref><figref num="5">FIG. 6 is a schematic cross-sectional side view of another device and method of making a protrusion that can be used as a hook fastener in accordance with the present disclosure.</figref><figref num="6">FIG. 6 is a schematic cross-sectional side view of another device and method of making a protrusion that can be used as a hook fastener in accordance with the present disclosure.</figref><figref num="7">FIG. 6 is a schematic cross-sectional side view of another device and method of making a protrusion that can be used as a hook fastener in accordance with the present disclosure.</figref><figref num="8">FIG. 6 is a schematic cross-sectional side view of another device and method of making a protrusion that can be used as a hook fastener in accordance with the present disclosure.</figref><figref num="9">FIG. 6 is a schematic cross-sectional side view of another device and method of making a protrusion that can be used as a hook fastener in accordance with the present disclosure.</figref><figref num="10A">FIG. 6 is a schematic front view of another device and method of making a protrusion that can be used as a hook type fastener in accordance with the present disclosure.</figref><figref num="10B">FIG. 6 is a schematic cross-sectional side view of another device and method of making a protrusion that can be used as a hook type fastener in accordance with the present disclosure.</figref><figref num="11">FIG. 10 is a schematic view of an article manufactured by the method and apparatus of FIG. 10A.</figref><figref num="12">FIG. 3 is a block diagram of an exemplary method according to the present disclosure for providing hook type fasteners.</figref><figref num="13">It is a schematic cross-sectional side view of another device and method of making a protrusion that can be used as a hook fastener, and according to the present disclosure, other materials may be supplied intermittently between the source of vibration and the substrate.</figref><figref num="14A">FIG. 3 is a sequential, schematic cross-sectional side view of an apparatus and method of making a protrusion that can be used as a hook fastener in an intermittent manner in place on a thermoplastic object in accordance with the present disclosure.</figref><figref num="14B">FIG. 3 is a sequential, schematic cross-sectional side view of an apparatus and method of making a protrusion that can be used as a hook fastener in an intermittent manner in place on a thermoplastic object in accordance with the present disclosure.</figref><figref num="14C">FIG. 3 is a sequential, schematic cross-sectional side view of an apparatus and method of making a protrusion that can be used as a hook fastener in an intermittent manner in place on a thermoplastic object in accordance with the present disclosure.</figref><figref num="15A">FIG. 3 is a sequential, schematic cross-sectional side view of another device and method of making a protrusion that can be used as a hook fastener in an intermittent manner in place on a thermoplastic object in accordance with the present disclosure.</figref><figref num="15B">FIG. 3 is a sequential, schematic cross-sectional side view of another device and method of making a protrusion that can be used as a hook fastener in an intermittent manner in place on a thermoplastic object in accordance with the present disclosure.</figref><figref num="15C">FIG. 3 is a sequential, schematic cross-sectional side view of another device and method of making a protrusion that can be used as a hook fastener in an intermittent manner in place on a thermoplastic object in accordance with the present disclosure.</figref><figref num="16A">FIG. 3 is a sequential, schematic cross-sectional side view of another device and method of making a protrusion that can be used as a hook fastener in an intermittent manner in place on a thermoplastic object in accordance with the present disclosure.</figref><figref num="16B">FIG. 3 is a sequential, schematic cross-sectional side view of another device and method of making a protrusion that can be used as a hook fastener in an intermittent manner in place on a thermoplastic object in accordance with the present disclosure.</figref><figref num="16C">FIG. 3 is a sequential, schematic cross-sectional side view of another device and method of making a protrusion that can be used as a hook fastener in an intermittent manner in place on a thermoplastic object in accordance with the present disclosure.</figref><figref num="17A">FIG. 3 is a sequential, schematic cross-sectional side view of another device and method of making a protrusion that can be used as a hook fastener in an intermittent manner in place on a thermoplastic object in accordance with the present disclosure.</figref><figref num="17B">FIG. 3 is a sequential, schematic cross-sectional side view of another device and method of making a protrusion that can be used as a hook fastener in an intermittent manner in place on a thermoplastic object in accordance with the present disclosure.</figref><figref num="17C">FIG. 3 is a sequential, schematic cross-sectional side view of another device and method of making a protrusion that can be used as a hook fastener in an intermittent manner in place on a thermoplastic object in accordance with the present disclosure.</figref><figref num="18">FIG. 5 is an enlarged cross-sectional view of an exemplary projection protruding from a substrate manufactured in accordance with the present disclosure.</figref><figref num="19">FIG. 3 is an enlarged cross-sectional view of an exemplary projection protruding from a layered substrate, manufactured according to the exemplary method of the present disclosure.</figref><figref num="20A">FIG. 5 is a top view of an exemplary masking material that will be used with the methods of the present disclosure.</figref><figref num="20B">FIG. 5 is a top view of an exemplary masking material that will be used with the methods of the present disclosure.</figref><figref num="21">FIG. 6 is a schematic cross-sectional side view of the device and method of FIG. 1 making a protrusion that can be used as a hook fastener, the masking material being combined with a substrate manufactured in accordance with the present disclosure.</figref><figref num="22">A schematic cross-sectional side view of the device and method of FIG. 1 making protrusions that can be used as hook fasteners, where masking material is used to achieve an intermittent pattern of protrusions on the substrate, but the mask , Not combined with substrates manufactured in accordance with the present disclosure.</figref><figref num="23">It is a perspective view of the apparatus of FIG.</figref><figref num="24">FIG. 6 is a schematic cross-sectional side view of the device and method of FIG. 1 making a protrusion that can be used as a hook fastener, and according to the present disclosure, a gasket material is provided for an intermittently patterned protrusion on a substrate Enclose the individual areas of the protrusion.</figref>

Molded hook fasteners are generally molded, for example, by extruding or injecting a thermoplastic melt onto a rotating drum or mold, the mold consisting of a stack or stack of metal plates, the plate being recessed or It is designed to provide a series of cavities along the perimeter that have knurled edges or can otherwise be filled with molten polymer. The protrusions formed in the cavity, or strip-like base portions through which the hooks can protrude, can be formed at the same time.

Instead of using an extrusion or injection process, it has been found that protrusions (hooks, mushroomheads, etc.) can be made by softening the polymer using vibrational energy in a relatively less complex and relatively inexpensive way. It was. In one exemplary embodiment, the thermoplastic substrate 11 is positioned or passes between the vibration source 13 and the rotomoulding roll 15, as shown in the schematic cross-sectional side view of FIG. The roll may have a plurality of hook-shaped or other shaped cavities 17 along the outer circumference. Substrate 11 may have films, sheets, webs, composites, laminates or other forms, but is not limited to these, or may be used, for example, as individual fastening tabs on disposable infant diapers. It may be a portion of a film, sheet, web, laminate or substrate thermoplastic that can be. For use in these infant diapers, the touch fasteners can be attached to the "side tabs" that the user uses to secure the diaper to the infant. These tabs may be configured with a piece of stretchable material that allows the tabs to stretch and bend when attached or when the infant moves. The present disclosure further contemplates the use of preformed films, sheets, webs, composites, laminates and the like as substrate materials.

During operation, the vibration source 13 is positioned in close proximity to the outer surface of the rotomoulding roll 15 and in contact with the substrate 11 of the thermoplastic material being processed. The vibration source 13 includes, for example, a vibration ultrasonic horn, but is not limited to this. These horns may be made from a metal such as aluminum or titanium and are sold by companies such as Branson Ultrasonics, Dukane or Sonitek in the United States and by companies such as Mecasonics in Europe. .. The vibration source 13 can vibrate at a frequency between about 50 Hz and about 50 kHz, if desired. Other sources of vibrational energy can also be used, including, but not limited to, rotational eccentric rollers, high pressure sound waves, or vibrational energy in the form of other mechanical and / or electromechanical or acoustic forms. .. Therefore, such energy can be transferred to the substrate and assist in the formation of protrusions herein.

The portion of the substrate 11 of the thermoplastic material in contact with the forming roll 15 and the vibration source 13 is softened by the vibrational energy from the vibration source and the desired portion of the thermoplastic material is placed in the cavity 17 of the forming roll. As the roll turns, hook-shaped or other shaped elements or protrusions 19 can be formed on the front surface of the film or sheet 21. This method can be called rotary forming. The reference to indentation can be understood as applying the required amount of pressure to the thermoplastic material to help the thermoplastic material enter and fill the cavity 17. The thermoplastic sheet 21 can function as a carrying strip for the hook 19.

Thermoplastic materials that can be used to make hook fasteners include polyamides, polyolefins such as polypropylene and polyethylene, acrylonitrile-butadiene-styrene (ABS), polyesters, polycarbonates, polyvinyl chloride (PVC) and mixtures thereof. However, it is not limited to these. The thermoplastic material may be modified or reinforced with fillers, fibers, flame retardants, colorants and the like.

One of the advantages of the present invention is that the thermoplastic material immediately next to the source of vibration does not have to melt, and thus most, if not all, of its original properties can be retained, i.e. It may not be affected by the thermal history, which can compromise the original properties.

When a pre-molecularly oriented material, or, as an alternative, a molecularly oriented material is used, the molecular orientation of the material entering the cavity is maintained, increased, or decreased by varying the applied vibrational energy. Can be done.

FIG. 18 is an enlarged cross-sectional view of an exemplary projection 19 as shown in FIG. 1 protruding from a substrate 21 manufactured according to the exemplary method of the present disclosure. At least in part, the temperature at which orientation is impaired due to the relatively small amount of heat given to the substrate by the vibrating action of the present disclosure (eg, Tg for amorphous polymers, or Tg for crystalline polymers). Orientation-dependent polymer properties can be more efficiently maintained and / or even increased in value compared to other processes in which the polymer is well above Tm). That is, the erecting portion 19A of the protrusion formed from the addition of vibrational energy substantially maintains or somewhat increases its molecular orientation when measured by the amount of contraction after formation or by its tensile strength after formation and before formation. May cause you to. For example, if the polymeric material has the tensile strength (TS) of TS1 in the direction of the orientation plane (eg, in the longitudinal direction, which can be understood as the direction of extrusion) before entering the cavity, the vibrational energy The protrusions formed by exposure may still exhibit tensile strength (TS2) in the direction of orientation of at least 50% or more (eg, up to 200%) of TS1.

Furthermore, if the amount of shrinkage due to orientation before exposure to vibrational energy has a given value (S1) in a given direction on the substrate, then in the protrusions that may exist after exposure to vibrational energy. The amount of shrinkage (S2) in the same direction can be at least 50% or more (eg, 150%) of its original value. That is, S2 0.50 (S1). As used herein, the term shrinkage can be understood as a reduction in dimensions that occurs when the substrate is heated beyond that to a temperature at which it loosens its orientation and disappears altogether. As described herein, this can exceed the glass transition temperature (Tg) for amorphous polymers and can be near the melting point (Tm) for crystalline polymers.

Furthermore, it is contemplated herein that it may start with a substrate that contains little or no orientation, which can be understood as a situation where the amount of shrinkage is 5.0% or less in any given direction. Will be done. It can also be characterized as a situation in which a given longitudinal Elmendorf tear strength (ETMD) is approximately equal to a given lateral Elmendorf tear strength (ETCD) for a given substrate. The horizontal direction can be understood as, for example, a direction that crosses the vertical direction (MD). That is, ETMD is within about +/- 20% of ETCD. Elmendorf tear strength can be measured by ASTM D1922 and can be understood as the average force required to propagate the tear over the length of the substrate. Therefore, for substrates that contain little or no orientation, the formation of protrusions for application of vibrational energy and mechanical engagement is relative to the totally non-oriented substrate from which the protrusions are formed. It can provide protrusions that include orientation. The orientation in such a protrusion may be such that it contains more than 5.0% shrinkage in a given direction.

Further, it is contemplated herein that it may start with a substrate having biaxial orientation, which can be understood as a situation with bidirectional orientation. For example, the vertical and horizontal directions can show relatively uniform shrinkage values in excess of 5.0%. Therefore, due to the ability to concentrate vibrational energy on the surface of the substrate during the formation of protrusions for mechanical engagement, the underlying substrate effectively retains biaxial orientation and is present within the substrate. It can be understood that the protrusions are formed without breaking the biaxial orientation in.

It should also be noted that with respect to the substrate and projection properties described above, one or more of such properties may be present in any given substrate / projection configuration.

When a multilayer material (laminated material) is available, one or more parts of the layered material should be formed in a cavity that allows the manufacture of a product in which the properties of the hook portion can be selectively manipulated. Can be done. FIG. 19 is an example of an enlarged cross-sectional view of an exemplary projection protruding from a layered substrate, manufactured according to an exemplary method of the present disclosure, such as that shown in FIG. Here, the second material 121 is connected to the substrate material 21, and the protrusion 19 is formed by the process according to the present disclosure. Part 122 of the second material 121 can extend into the body or upright portion 19A of the protrusion 19 and can impart enhanced properties to the protrusion. For example, the portion 122 formed from the substrate material 121 can have a shore hardness value different from the shore hardness value corresponding to the substrate material 21.

When multi-layer laminates are utilized, the fastener elements can be manufactured from one or more colors and the strip-like base may be of different colors. In addition, if a multilayer laminate with a transparent surface layer is used, the fastening element or strip-like material may be formed transparent.

Unlike prior art taught in the art, where the raw material is in a molten state before forming the substrate in the form of a web and including integral protrusions, the present disclosure uses vibrational energy to soften the polymer. By forming it into the desired shape and thereby minimizing the thermal history of the polymer being processed, the substrate material retains the desired properties such as molecular orientation, multicolored layers or composite structures. To enable.

With reference to FIG. 1, a means for cooling can be provided on or adjacent to the molding roll 15 to form a molding, i.e. a polymer strip 21 containing a plurality of hook-type protrusions 19. Can be peeled off from. Cooling is, for example, cooling the molding roll externally and / or internally, cooling the vibration source internally and / or externally and / or directly and / or liquid, gas, air the thermoplastic material. It can be achieved by cooling indirectly by using or other means.

In some cases, an afterburst of ultrasonic energy may be applied during or after cooling to help "separate" the protrusions from the mold or horn. This can be especially useful when protrusions are formed on the surface of the energy source, i.e. the horn.

FIG. 12 shows an example of a process for realizing a protrusion on a substrate that can be used as one of the joints in a touch fastening system. As described in block 100, molding rolls or other shapes can be provided that have multiple hook-shaped or other shaped cavities arranged along the perimeter of the molding roll, the cavities. , It is possible to form protrusions that match the shape of the cavity. Block 200 may provide a vibrational energy source such as an ultrasonic horn or roll. Substrate materials may be provided in the form of, for example, films, sheets, webs, laminates, composites, etc. (block 300), where the substrate is positioned between the molding roll and the source of vibration (block 400).

The vibration source can be energized (block 500) to selectively soften the substrate material and put the material into a cavity in the molding roll to form protrusions. Alternatively, the forming roll may be flat and the cavities for forming the protrusions may be formed within the surface of the vibration source shown in FIGS. 5, 7 and 8.

If desired, the protrusions and the substrate may be cooled, and the substrate containing the protrusions extending from its surface can be peeled off the molding roll to form strips for use in touch fastener systems. Cooling may be performed between the molding roll and the vibration source, in the molding roll or on the substrate after leaving the roll. The protrusions can then be post-formed into the desired shape.

As described herein, the cavity for forming the protrusion may be formed within the surface of the rotating horn (see FIGS. 4-8).

Hook-shaped cavities and hook-shaped protrusions are referred to herein, but include straight pins, angled pins, tapered pins, pins with mushroom heads, and curved pins, and to these. Examples include, but are not limited to, elements with different cross sections such as circular, oval, square, rectangular, trapezium, cross, multi-leaf, hook-hook, multi-limb or combinations thereof. It is expected that the cavity may be selected to produce protrusions with other shapes that can, but are not limited to, serve as the "hook" portion of the touch fastener system. The protrusions may include a solid core or may be in a hollow form such as tubular. Some examples of these shapes are shown in Figures 2A-N. For example, FIG. 2G is an example of a multi-leaf protrusion, FIG. 2I is an example of a tubular, FIG. 2J is an example of a cruciform, FIG. 2K is an example of a Y-shape, and FIG. 2L is an example of a Y-shape. , A hook-shaped example, and Fig. 2M is an example of multiple limbs. Furthermore, if FIG. 2J is an example of a four-limb process and FIG. 2K is an example of a three-limb process, the process may have more limbs, such as 5, 6, 7, 8. It is planned. Such protrusions may vary in height, thickness, and angle at which the protrusions can protrude from the carrying strip 21 or substrate. In addition, the protrusions may be formed at uniform heights or may vary in height.

The surface of the vibration source 13 can be shaped to extend the time that the thermoplastic material can be exposed to vibrational energy, or otherwise improve the properties and / or performance of the method. FIG. 3 shows an example of a modified surface type of vibration source 13A, where a portion of surface 12A of vibration source 13A is provided that is complementary in shape to the surface of molding roll 15. Also in FIG. 3, in this example, the vibrating surface portion 12 is modified as a complex curved surface to allow the thicker thermoplastic material 11A to pass between the vibrating source 13A and the forming roll 15. Has been done. The shaping of the vibration source 13A can also be used to reduce distortion of the finished product and help guide the substrate 11 of the thermoplastic material between the vibration source 13 and the rotomoulding roll 15.

In another exemplary embodiment, as shown in FIG. 4, the vibration source may be a roll that can have cavities for forming protrusions, and the rotating roll 22 is a softened thermoplastic. It may be positioned to push into the cavity. The rotational source 20 may include multiple hook-shaped or other-shaped cavities 17 along its perimeter and is used in place of the fixed sources 13, 13A (as shown in FIGS. 1 and 3). And may be positioned close to the rotary roll 22. The vibration source 20 may be a rotary ultrasonic horn. These horns may be made of titanium, for example, and in the United States Branson Sold by Ultrasonics and in Europe by Mecasonics. If patterning of the back 24 of the product is desired, a roll with a patterned surface may be used instead of the flat roll. Patterning on the back of the product to mimic a woven structure or leather material or other design can work to enhance the aesthetics and / or functionality of the product. In some cases, the patterned surface can be designed on one or both rolls to form holes in the base material, thereby making the fasteners breathable or permeable.

In another exemplary embodiment, as shown in FIG. 5, a rotational vibration source 20 having a plurality of hook-shaped or other shaped cavities 17 along its perimeter, as shown in FIG. 4, is non-rotating fixed. It can be positioned close to the platen 26. The platen surface 28 may be flat or patterned if patterning of the back surface of the product is desired.

FIG. 6 shows an exemplary embodiment of another type of modified fixed pressure plate 30 with a rotary vibration source 20. In this example, one surface 32 of the platen is modified as a complex curved surface in this example to allow a thicker thermoplastic material (board) to pass between the vibration source 20 and the modified fixed platen 30. There is. Reference numeral 32A indicates a region where the surface shape of the platen 30 is complementary to the surface shape of the rotary vibration source 20. The shaping of the modified fixed pressure plate 30 can also be used to reduce distortion of the finished product and help guide the thermoplastic material substrate 11A between the rotational vibration source 20 and the fixed pressure plate 30. The platen surface 32 may be flat or patterned if patterning of the back surface of the product is desired.

In another exemplary embodiment, as shown in FIG. 7, a rotational vibration source 20 having a plurality of hook-shaped or other shaped cavities 17 along its outer circumference is placed on both the front and back of the seat 21A. It can be combined with a rotomoulding roll 15 (as shown in FIG. 1) to produce polymer strips with protrusions. The rotational vibration source 20 can be positioned close to the outer surface of the rotomould roll 15, and both rolls can include a plurality of hook-shaped or other shaped cavities 17 along its perimeter thereof. As shown, this allows the manufacture of products with hook-shaped or other shaped elements 19 simultaneously on the front 23 and back 24 of the carrying strip 21A.

In another exemplary embodiment, as shown in FIG. 8, a rotary oscillating source 20 having a plurality of hook-shaped or other shaped cavities 17 along its outer circumference has a plurality of hook shapes along its outer circumference. It can be positioned in close proximity to another rotational vibration source 20A having a cavity 17 of or other shape. This will allow the manufacture of products with hook-shaped or other shaped elements 19 on the front 23 and back 24 of the carrying strip 21A at the same time.

In yet another exemplary embodiment, two or more sources of vibration, either fixed or rotary in nature, can be used simultaneously. FIG. 9 illustrates the use of two fixed sources 13 in close proximity to a rotomoulder roll 15 having a plurality of hook-shaped or other shaped cavities 17 along the perimeter of the forming roll 15.

As mentioned above, the methods and devices according to the present disclosure can function as hook fasteners or protruding elements with other shapes in a touch fastening system on one or more surfaces of a strip of thermoplastic substrate. Suitable for forming products with protrusions, the substrate has forms such as films, sheets, webs, composites, laminates or other forms, or parts thereof. The substrate may have a cellular structure, such as a foamed polymer, or may be a molecularly oriented film or a composite material, which may include, for example, a fiber reinforced plastic. The protrusions can have various shapes, lengths and dimensions. The protrusions may be formed from one or more of the materials that make up the multilayer film or substrate sheet or parts thereof.

It is contemplated that at least a portion of the substrate may contain a thermosetting polymer.

It is further contemplated that the substrate on which the protrusions are formed may contain materials of continuous or intermittent layers and combinations thereof. For example, it is contemplated that protrusions can be formed on the intermittent web, perhaps to manufacture diaper closure tabs according to a diaper making machine.

The protrusions may be formed into their final shape, or, for example, straight pins that can be reshaped into hook shapes in a later processing step, or straight pins that can be rounded to a mushroom shape, or It is further contemplated that the hooks may be partially shaped and manufactured and post-formed to obtain the final shape, such as modified hooks that can be post-formed into hooks capable of functioning as fastening elements.

The protrusions formed herein are either by engaging with a material having a loop element (eg, a structure that mechanically engages with a protrusion such as a hook), or a screen-like material, open cell foam-like. Further, by engaging with a material of, or a material having similar or joining protrusions (eg, hooks, mushrooms, etc.), either temporary or permanent means of fastening can be provided. It is planned.

In the specific advantages of the methods described herein, the protrusions of the present disclosure can be turned on / off of the vibration source as needed, or the location and / or contact force and / or vibration frequency of the vibration source. Can be formed intermittently on the substrate by intermittently changing. For example, the ultrasonic horn or other source of vibration can be moved up and down intermittently while the web intermittently forms protrusions on the substrate via the method. Thus, the protrusions can be formed in the desired pattern, which may change during in-line processing of the substrate. Therefore, the protrusions can have a uniform height or multiple levels of height, depending on the operating conditions of the device.

According to the present disclosure, the protrusions can be formed on a substrate such as a web, and this portion of the web is formed in a crepe or folded to allow expansion and contraction of the web. FIG. 10A is a schematic front view showing an exemplary embodiment of the configuration of the device, wherein the molding roll 42 includes a portion 44 of the surface having a cavity for forming a protrusion element, a vibration source 40 and a molding. Roll 42 contains complementary portions of its surfaces 46, 46A, each configured to form a crepe region. FIG. 10B is a schematic cross-sectional side view of FIG. 10A. FIG. 11 represents an example of a product that can be manufactured from the configuration shown in FIG. 10A. In this example, the hook type element 19 is formed adjacent to the crepe region 48 on the web 21B. This type of configuration is used to form hook elements and crepe areas on diaper closure tabs to eliminate the complex combination of touch fasteners bonded to the elastomeric non-woven fabric currently used in this application. It turns out to be attractive. Thus, the crepe portion and the fastening portion can be formed on the web material at the same time so that an extensible diaper fastening tab is formed. One of the surfaces 46, 46A can be configured to form a crepe region, or one of these surfaces is fitted with a rubber or elastomer that matches the opposing surface configuration under nip pressure. Can include (compliant) materials. The reference crepe can be understood to mean the quality on the web that is imparted by embossing to obtain a wavy surface such as web folds. The reference to a wavy surface can be understood to mean a surface whose relative position moves up and down.

In another exemplary embodiment, the protrusions can be formed while simultaneously attaching the protrusions to the stretchable or non-stretchable web. As shown in FIG. 13, the extensible or non-extensible material 11B forms a rotary forming roll 15 and a fixed vibration source 13 (or a rotary vibration source or protrusions as disclosed herein). Can be supplied between molds and other configurations of vibration sources) (see, eg, FIGS. 1, 3-9, 10A and 10B). The vibration source 13 can be positioned close to the mold 15, but far enough away to avoid melting or modification of the extensible or non-extensible material 11B. Pieces of thermoplastic or thermosettable material 18 can be supplied intermittently between one or more sides of stretchable or non-stretchable material 11B and the vibration source 13. When this piece passes between the source 13 and the mold roll 15, for example, with additional thickness, the thermoplastic or thermosettable material can be tucked into the cavity 17.

In addition, the pattern of protrusions allows a pre-perforated or pre-die-cut masking material to pass between the substrate (film, sheet, composite, etc.) and the molding roll, thereby selectively covering the area of the molding roll. , Can be formed by realizing an intermittent pattern of protrusions. The mask may be removed if necessary (Fig. 22) or bonded to the substrate (Fig. 21). Therefore, the pattern change can be realized relatively easily without the need to change the composition of the forming roll. Die-cutting or other formation of the mask can be done in-line or offline.

Figures 20A and 20B show examples of masking materials for such purposes. FIG. 20A is a top view of the mask 80 including a material sheet 82 such as paper, metal, film, fabric, etc., in which one or more openings 84 are formed. FIG. 21 shows the apparatus and method of FIG. 1, in which the mask 80 in sheet form is fed to the nip between the vibration source 13 and the forming roll 15, whereby a portion of the mask is provided in the selected cavity 17 in the forming roll. An intermittent pattern of protrusions 19 is formed on the surface of the formed substrate 21 through the openings 84.

FIG. 22 shows a similar method, where the mask 80 does not have to be separated from the substrate 21 and made part of the finished product.

FIG. 23 is a perspective view of the device and method of FIG.

FIG. 24 shows another device and method similar to FIG. 1, in which the sheet form material 90 (foam, non-woven web, etc.) is laminated on the substrate material 11 and between the vibration source 13 and the forming roll 15. Supplied to the nip. Part 100 of the forming roll 15 to allow the part of material 90 to achieve an intermittent pattern of protrusions 19 and also to allow material 90A to surround the individual areas of protrusion 19 and act as a gasket. However, it may be removed. Thus, as shown, the intermittently patterned protrusions 19 are formed like islands between regions of material 90A. The layer 11 of the thermoplastic material impregnates the material 90 when the protrusions 19 are formed. The height of the protrusions 19 may be less than the height of the material 90A, which is intended to prevent the protrusions from engaging with the joint fastening system elements, effectively hindering premature engagement. In applications such as diaper fastening tabs, this can also protect the protrusions from contact with the baby's skin.

It is also contemplated that the protrusions can be formed through openings in the material coating layer by passing multiple material layers between the forming roll and the vibration source, where the coating layer is within one or more of the rolls. Perforated holes may be included in the pattern of the cavities, or porous materials such as textiles can provide openings for the substrate material to penetrate and be pushed into the cavities in the roll. The strength of the coating layer is weak enough for the substrate material to break through the coating material and enter the cavity of the mold.

FIG. 20B shows a porous substrate material such as a screen, non-woven, open cell foam covered by a coating or by laminating another material 86, except for areas where openings 84 are formed within the coating. Shown is another type of mask 80A made from 88. The porous material 88 is visible through the opening 84 so that the protrusions can form through it, while the covering area of the mask acts to prevent the formation of the protrusions 19. It is further contemplated that the mask can be applied locally directly to a portion of the surface of the molding roll, such as by spraying or dipping a liquid and then drying it. This coating can then prevent the formation of protrusions in selected areas of the substrate. The mask can be used repeatedly or can be peeled off and reapplied.

In addition, to achieve a pattern of back-to-back projections with multiple layers of laminate, eg, a reinforcing layer, the thermoplastic substrate / fabric / thermoplastic fabric is a synergistic roll and vibration source (see, eg, FIGS. 7 and 8). ) Can be passed.

It is further contemplated that intermittent cuts or slits or other shaped holes can be made in the substrate by raising a portion of the molding roll surface (or rotary horn surface) to create a notch or a very thin portion of the substrate. Will be done. These modifications to the substrate may work to make the fastening strips softer and / or stretchable and / or breathable.

The methods and devices described herein are superior to extrusion / molding methods because they require relatively low heating and cooling energy consumption because only the material used to form the protrusions needs to be heated and cooled. It can bring benefits. In addition, multiple colors can be achieved through the selection of substrate materials and a wide variety of properties can be obtained through the selection of substrate materials, including but not limited to molecularly oriented substrates or composite substrates. Materials printed with patterns, logos, etc. may be used as substrates, thereby allowing protrusions to form on one or more of their surfaces, keeping the printed patterns, etc. discernible. to enable. The start time of the method may be relatively short, the method can be started and interrupted at will, and of the complex and costly automatic transfer winder often required in continuous extrusion processes. There is no need. Ultimately, the floor space required can be significantly reduced.

Touch fasteners are often glued to a variety of thermoplastic objects. One such application is the attachment of touch fasteners to automotive door panels and inner ceiling material panels. Materials selected for use as touch fasteners (polyamides, polyolefins, etc.) often make adhesive junctions difficult, costly, and often a source of damage. Versions of the methods and devices described herein combine the fasteners with the base material so that hook-type fasteners (protrusions) can be formed as part of or on the surface of such base material. It is contemplated that the need for adhesives can be eliminated or reduced.

The methods and devices described so far are primarily intended for continuous or semi-continuous methods of forming protrusions on various surfaces. In another exemplary embodiment, which can be described as "plunge formation", an automatic device, robot-held or hand, which can bring the formation of protrusions where desired. Protrusions can be formed anywhere on a thermoplastic object using a horn or other source of vibration held in. 14A, B and C show a method in which the ultrasonic horn 54 can have a vibrating surface 50 that can be configured with a cavity 17 located above it (FIG. 14A). The ultrasonic horn 54 presses against a thermoplastic object 52 (eg, a vehicle door panel or ceiling substrate) (arrow A) and applies vibrational energy (FIG. 14B) to selectively soften the thermoplastic material. A portion of the thermoplastic material 52 can be tucked into the cavity 17. The vibrational energy is then stopped, the thermoplastic material is cooled, the ultrasonic horn recedes (arrow B, FIG. 14C), releasing the newly formed protrusion 19 from the cavity 17, and a local pattern for mounting. Protrusions can provide a plastic object with a surface formed on it.

In some cases, an afterburst of ultrasonic energy can be applied during or after cooling is performed to help "separate" the protrusions from the mold or horn. This can be especially useful when protrusions are formed within the surface of the energy source, i.e. inside the horn. It is contemplated that a removable or replaceable horn tip can be used to allow the pattern of protrusions to change at a relatively high speed.

Similarly, FIGS. 15A, B and C show that various thermoplastic or thermosettable materials 60 can be positioned between the ultrasonic horn 54 and the object 52 (FIG. 15A) and complete from the positioned material 60. It is shown that it allows the formation of protrusions 19 either or partially (Fig. 15B). Thus, the protrusion 19 can be formed from the second material 60 by a vibration treatment that allows the material to bond to the object 52 (FIG. 15C). This is especially useful in situations where the object 52 is an automotive trim panel that can be understood as a thermoplastic and / or thermosetting door panel, instrument panel, central console, rear close-out panel, ceiling material, etc. I can understand that there is.

In another exemplary embodiment, the cavity can be realized within the shaped base 56 rather than within the ultrasonic horn 54, as shown in FIGS. 16A, B and C. The thermoplastic object 52 can be positioned between the ultrasonic horn and the mold base 56 (FIG. 16A) and held under pressure (arrow A, FIG. 16B). Vibrational energy is applied to the horn (FIG. 16B), allowing a portion of the material from the object 52 to be pushed into the cavity 17 of the base. Also, the vibrational energy is stopped, the thermoplastic material is cooled, the ultrasonic horn recedes (arrow B) (FIG. 16C) and the newly formed protrusion 19 is released from the cavity 17 and is localized for mounting. It is possible to realize a plastic panel with a surface on which the protrusions of the pattern are formed.

17A, B and C show that various thermoplastic or thermosetting materials 60 can be positioned between the object 52 requiring the protrusion 19 and the shaped base 56 having the cavity 17 (FIG. 17A). Is shown. The protrusions can be formed from the material 60 by pressing the horn 54 and the mold 56 around the object 52 and the material 60 and applying vibrational energy (arrow A, FIG. 17B). Also, the vibrational energy is stopped, the thermoplastic material is cooled, the ultrasonic horn recedes (arrow B) (Fig. 17C), releasing the newly formed protrusion 19 from the cavity 17, a material different from the object 52. Realizes a plastic panel with a surface formed on which local patterned protrusions of.

The methods and devices described herein are hook-type materials because different types of materials are supplied to the device in layers and protrusions can be formed on or through one or more of the layers. The complexity of inserting and molding into a larger molded object can be significantly reduced. Therefore, the material for a portion of the substrate layer or for the protrusions may be different from the substrate material. The use of ultrasonic horns or other vibrational energy sources and the pattern of protrusions on the surface of an object to form protrusions on an object in a discontinuous or intermittent manner as disclosed herein. The use of pattern-like bases to form locally can provide a highly flexible method that can be easily moved with relatively low capital and space requirements. It is contemplated that all of the features disclosed for continuous or semi-continuous methods herein can also be applied to locally mount protrusions on an object.

The protrusions disclosed herein for use as elements in a touch fastening system can be manufactured in a relatively wide range of sizes and densities to achieve a wide range of fastening or holding strengths. Without being bound by any specific restrictions, it is conceivable that the height of such protrusions can range from less than about 10 microns to more than about 5 mm.

The present specification and drawings illustrate the currently preferred embodiments of the present invention. The present specification and drawings are intended to illustrate these embodiments and are not intended to limit the scope of the invention. Those skilled in the art will appreciate that yet other modifications and modifications of the invention are possible in the light of the above teachings within the appended claims. Therefore, within the scope of the claims, the present invention can be practiced in a manner different from that specifically shown and described herein and the drawings.

The following applications are also presented in this application. [Item 1] It is a method of forming protrusions on a substrate. With the steps to provide a mold with an outer surface, Steps to provide a substrate material with a surface, A step of providing a device as an oscillating energy source, wherein one or both of the mold and the device has a plurality of cavities, and the cavities have a shape. A step of positioning the substrate material between the mold and the device, A step of energizing the device, in which a portion of the substrate material enters the cavity inside the mold surface of the mold. Including the step of forming a protrusion on at least a part of the surface of the substrate material. The cavity is shaped to form a protrusion, which is a hook, mushroom, straight pin, angled pin, tapered pin, curved pin, hook hook, multiple limbs, cross, Y A method that is formed like one or more of a letter shape, and a multilobed shape, each having a circular, oval, square, rectangular, trapezium, solid, hollow, or a combination thereof. [Item 2] The method of item 1, wherein the substrate material is pushed into the cavity. [Item 3] The method of item 1, wherein the formed substrate further comprises a crepe region made from one or both parts of the mold having a corrugated surface and the device. [Item 4] The method of item 1, wherein the energization of the device is intermittent. [Item 5] The method of item 1, wherein the substrate material comprises a thermoplastic and / or thermosetting material. [Item 6] The method of item 1, wherein the mold comprises a rotating roll. [Item 7] The method of item 1, wherein the mold comprises a rotary roll and the device comprises a rotary roll. [Item 8] The method of item 1, wherein the mold is fixed and the device comprises a rotating roll. [Item 9] The method according to item 1, wherein the vibration energy is mechanical, electromechanical, or acoustic. [Item 10] The method of item 1, wherein the device comprises an ultrasonic horn. [Item 11] The method of item 1, wherein the substrate material enters the cavity within the surface of the mold forming the protrusion, and a portion of the substrate acts as a carrying strip for the protrusion. [Item 12] The substrate comprises a laminate and has a first layer containing one or more openings that expose the surface of the second layer, the projections being formed on the surface of the second layer. The method described in item 1. [Item 13] The method of item 1, wherein the substrate has a laminate comprising layers of different materials, continuous and / or intermittent, including foam, fiber reinforced plastic, oriented thermoplastic or thermosetting material. [Item 14] The method of item 1, wherein the protrusions are post-formed into the desired shape after being removed from the cavity. [Item 15] The method of item 14, wherein the post-formation uses vibrational energy. [Item 16] 14. The method of item 14, wherein the protrusions are post-formed to include mushroom-shaped heads. [Item 17] As a subsequent step, the protrusion engages a second substrate material having one or more of loop elements, complementary shaped protrusions or other joining features to bring the substrate material into the second substrate material. The method according to item 1 for fastening to a substrate material. [Item 18] The method of item 1, wherein vibrational energy is applied to the protrusions to help remove the protrusions from the cavity. [Item 19] A second thermoplastic material passes between the substrate material and the mold or device, the second thermoplastic material is exposed to the vibrational energy, and the second substrate material becomes the substrate material. The method according to item 1 for bonding. [Item 20] 19. The method of item 19, wherein the second thermoplastic material forms at least a portion of the protrusion. [Item 21] The method according to item 1, wherein the substrate includes a part of a diaper. [Item 22] The method according to item 3, wherein the substrate includes a part of a diaper. [Item 23] 7. The method of item 7, wherein one or both of the rolls comprises a patterned surface, the patterned surface forming holes in the substrate. [Item 24] It is a method of forming protrusions on a substrate. Steps to provide a substrate material with a surface, A step of providing a device as a vibration energy source, wherein the device has a surface having a plurality of cavities, the cavities are arranged along at least a part of the surface, and the cavities have a shape. When, The step of pressing the device against the surface of the substrate material, It is a step of energizing the device, pushing a part of the substrate material into the cavity in the surface of the device, and forming a protrusion on the surface of the substrate material, wherein the protrusion as a whole is the cavity. Including steps that match the above-mentioned shape of The cavity is shaped to form a protrusion, which is a hook, mushroom, straight pin, angled pin, tapered pin, curved pin, hook hook, multiple limbs, cross, Y A method that is formed like one or more of a letter shape, and a multilobed shape, each having a circular, oval, square, rectangular, trapezium, solid, hollow, or a combination thereof. [Item 25] 24. The method of item 24, wherein the device is manually or robotically pressed against the surface of the substrate material. [Item 26] 24. The method of item 24, wherein the protrusions are post-formed into the desired shape after being removed from the surface of the mold. [Item 27] 26. The method of item 26, wherein the post-formation uses vibrational energy. [Item 28] 26. The method of item 26, wherein the protrusions are post-formed to include mushroom-shaped heads. [Item 29] A second thermoplastic material passes between the substrate material and the device, and the second thermoplastic material is exposed to the vibrational energy to bond the second substrate material to the substrate material. The method described in item 24. [Item 30] 24. The method of item 24, wherein the substrate comprises an automotive trim panel. [Item 31] A device that forms protrusions on a substrate A mold with a surface and Equipped with a device as a vibration energy source, One or both of the mold and the device has a plurality of cavities, said cavity having a shape, said shape with one or more of loop elements or complementary shaped protrusions or other bonding materials. A device that realizes the formation of protrusions from a substrate suitable for mechanical engagement. [Item 32] 31. The device of item 31, wherein the mold and one or more of the devices include rolls. [Item 33] 31. The device of item 31, wherein the vibrational energy is mechanical or electromechanical or acoustic. [Item 34] 31. The device of item 31, wherein the device is an ultrasonic horn. [Item 35] The device has at least a partially curved surface that engages a first side surface of the substrate, and a second side surface of the substrate engages at least a partially curved surface of the mold. The device of item 31, wherein the device and the curved surface of the mold are complementary in shape. [Item 36] 35. The device of item 35, wherein the complementary curved surface further forms a crepe region. [Item 37] 35. The apparatus of item 35, wherein the curved surface of the mold comprises a compatible material. [Item 38] 31. The apparatus of item 31, wherein the formed substrate comprises an extensible fastening tab for a diaper. [Item 39] A device that forms protrusions on a substrate The device comprises a device as a vibrational energy source, the device having a plurality of cavities, said cavity having a shape, said shape being mechanically engaged with a loop element or a complementary shaped protrusion or other bonding material. A device that realizes the formation of protrusions in a substrate suitable for. [Item 40] An article for mechanical engagement, comprising a substrate having two sides and containing one or more protrusions extending from one or both sides, said substrate being longitudinal (MD) and lateral. In an article with a direction (CD) i. The substrate has a tensile strength TS1 in the longitudinal direction, and the one or more protrusions have a tensile strength TS2, where TS2 is 50% or more of the value of TS1. That and ii. The substrate has a shrinkage amount S1 in a given direction, and the one or more protrusions have a shrinkage amount S2 in the same direction, and S2 0.50 (S1). An article that has one or more of the characteristics of. [Item 41] An article for mechanical engagement, comprising a substrate having two sides and including a plurality of protrusions extending from one or both sides, said substrate prior to forming protrusions on the surface of the substrate. , Vertical (MD) and horizontal (CD), the substrate is biaxially oriented to indicate shrinkage values in which the amount of shrinkage in the vertical and horizontal directions is within the range of +/- 20% of each other. The substrate is biaxially showing a shrinkage value in which the amount of shrinkage in the vertical direction and the horizontal direction is within the range of +/- 20% of each other after forming protrusions on the surface of the substrate. An article with orientation.

11 board 11A thermoplastic material 11B Stretchable or non-stretchable material 12 parts 12A surface 13, 13A vibration source, fixed vibration source 15 Molding roll 17 Cavity 19 protrusions 19A Standing part 20, 20A rotary vibration source 21 film or sheet 21A sheet 21B web 22 Rotating roll 23 Front 24 back 26 Non-rotating fixed pressure plate 28 Plate surface 30 Modified fixed pressure plate 32 surface 40 Vibration source 42 Molding roll 44 parts 46, 46A surface 48 crepe area 50 Vibration surface 52 Thermoplastic object 54 ultrasonic horn 56 base 60 Thermoplastic or thermosetting materials 80, 80A mask 82 Material sheet 84 opening 86 material 88 Porous substrate material 90, 90A material 100 parts 121 Second material 122 parts