Method and apparatus for producing hook fasteners

[0001] The present application reserves the benefit of US interim application US 61 / 145.883 filed on January 20, 2009.

FIELD [0002] The disclosure relates generally to mechanical fastening elements such as hook and loop fasteners (Velcro fasteners) or tactile fasteners (tactile fasteners), and more particularly to a method and apparatus for producing "hook" fasteners using vibration energy.

BACKGROUND [0003] Tactile fasteners (known under the trade names Velcro^®, Scotchmate^®, Tri-Hook^®, etc.) were originally manufactured using textile technology. Two of the most common types of tactile fasteners are hook and loop fasteners and mushroom-loop fasteners.

[0004] The hook-and-loop fastening means may comprise a pair of textile tapes. These textile tapes can cooperate with each other to form a reusable closure - one of the cooperating parts is a textile fabric tape comprising a plurality of monofilaments shaped like hooks that protrude from one surface and the other of the cooperating parts is in the form of a textile tape with woven multifilament elements on loop-shaped tabs on one surface. When the cooperating surfaces of these tapes are pressed against each other, the plurality of hook-shaped elements located on one tape grip the loop elements on the opposite tape and form a temporary, reusable connection. When the tapes are torn away from each other,

[0005] In the case of mushroom-loop fastening elements, the hook-type cooperating tape is replaced by a tape comprising a plurality of monofilament-shaped tabs having the shape of mushrooms or rounded heads. The mushroom-shaped heads can be shaped by heating the ends of straight monofilament tabs until a "mushroom head" is formed on each protrusion. When such a belt is compressed together with the tape comprising a loops-shaped tab on the surface, the mushroom heads can grasp the loop elements on the opposite tape and form a temporary, reusable connection. When the tapes are torn away from each other, the mushroom elements can be temporarily deflected, releasing the loop elements. In addition, two tapes, each having mushroom tabs,

[0006] Recently, it has become popular to use methods for the production of such tactile fastening elements based on thermoplastic extrusion / molding. In the case of hook and loop fastening elements, the hook tape can be formed by extruding the polymer into a web shape with integrated tabs, while the loop band can still be produced using technology related to fabrics, knits or nonwovens. In the case of mushroom-loop fastening elements, the hook tape can be produced by extruding the polymer into a ribbon shape with integrated tongue-like protrusions and end-molding of mushroom-like heads on peg-like protrusions.

[0007] The use of extrusion / molding technology for the manufacture of tactile hook and mushroom type attachment elements has resulted in reduced manufacturing costs and improved parameters and appearance of the tactile fasteners, thus enabling their use in a large number of applications, e.g. as fasteners in disposable diapers. .

[0008] Examples of technologies used to manufacture the extrusion / molded tactile fastening elements include:

• Embossing / forming a hook fastening element with an integrated base, wherein the base may be formed on a forming roller, wherein the hook elements may be formed in separate recesses. The mold can be opened and closed continuously as it rotates to allow removal of the hooks (see, for example, U.S. Patent No. 3,762,000 and 3,758,657 and 3,752,619, to Menzin and 3,196,490 to Erb).

• Embossing / forming a hook fastening element with an integrated base, where the hook elements can be formed in separate recesses, the mold remaining closed. Hooks can be removed from the mold cavities after they have cooled. The geometry of the hooks may therefore be somewhat limited because the hooks must be removable from the closed mold (see, for example, U.S. Patent Nos. 3,312,583 and 3,541,216 (for Rochlis); 4,775,310 and 4,794,028 (for Fischer); and 5,393,475 (for Murasaki) )).

• Embossing a web of material with a series of strips with a hooklike cross-section that extend parallel along the upper surface of the web. The strips may be cut in a non-continuous manner up to the base material. The base material may be stretched to provide spacing between the hook elements (see, for example, U.S. Patent Nos. 3,665,504 and 3,735,468 (to Erb)).

• Embossing a web of material with a plurality of formed pegs or the like, followed by final forming of the elements to form a hook-type or mushroom-type fastening element (see, for example, US Patent No. 3,182,589; 3,270,408; 5,607,635; 5,755,015; 5,781,969 and 5,792,408.) 0009] One common feature of all these processes is the melting and insertion of a thermoplastic material using an extruder or similar device. Extrusion / molding technologies are often regarded as efficient ways of making tactile fasteners, but they can usually require significant capital investment in basic equipment (extruders, refrigerators, pumping systems, dryers, granule transport systems), high energy consumption during the process,

[0010] There is a need for a method and apparatus for manufacturing hook type fastening elements intended for use in a closing system, in particular in a reusable closure system, in the case of which there are no large capital investments described above and low efficiency in using materials.

[0011] DE 10102501 A1 describes a method according to the invention for producing a film with a surface structure in which the thermoplastic material is introduced into the mold, and cavities of the mold are used to obtain the structure effect on the film. The thermoplastic material penetrates into the mold cavities. After removing the thermoplastic material from the mold, the surface of the thermoplastic material comprises a structure obtained using these mold cavities. For this purpose, the thermoplastic material is introduced into the mold using ultrasound.

SUMMARY [0012] In one exemplary embodiment, the present invention relates to the method of claim 1.

[0013] In another exemplary embodiment, the present invention relates to a device according to claim 9.

[0014] The present disclosure also relates to a mechanical engaging product, which product comprises a substrate with two sides and one or more projections extending from one or both sides, the substrate having machine direction (MD) and transverse direction (CD). and the product is characterized by one or more of the following characteristics:

i. the substrate has a tensile strength in said machine direction of TS1 and one or more projections has a tensile strength TS2, where TS2 is equal to 50% of TS1 or greater; or ii. the substrate has a shrink in a given direction of S1, and one or more projections have a shrink in the same direction of S2, S2> 0.50 (Si). [0015] The present disclosure also relates to a mechanical engaging product, which product comprises a two-sided substrate and one or more projections extending from one or both sides, the substrate having, prior to forming the projection in the substrate surface, the machine direction (MD). ) and lateral direction (CD), and the substrate is characterized by a biaxial orientation,

BRIEF DESCRIPTION OF THE DRAWINGS [0016] The accompanying drawings, which are incorporated in and constitute a part of this description, show embodiments of the invention and together with this description serve to explain the principles of the invention.

FIG. 1 is a schematic cross-sectional side view of the device and method of forming tabs that can be used as hook-type fastening devices of the present disclosure.

FIG. 2A-N are schematic views of exemplary vertical shapes that can be used as projections according to the present disclosure. FIG. 3 is a schematic side view of a cross-section of another device and method of making tabs that can be used as hook-shaped fasteners in accordance with the present disclosure.

FIG. 4 is a schematic side view of a cross-section of another device and a method of making tabs that can be used as hook-like fasteners in accordance with the present disclosure.

FIG. 5 is a schematic side view of a cross-section of another device and a method of making tabs that can be used as hook-shaped fasteners in accordance with the present disclosure.

FIG. 6 is a schematic side view of a cross-section of another device and a method of making tabs that can be used as hook-shaped fasteners in accordance with the present disclosure.

FIG. 7 is a schematic side view of a cross-section of another device and method of making tabs that can be used as hook-shaped fasteners in accordance with the present disclosure.

FIG. 8 is a schematic side view of a cross-section of another device and a method of making tabs that can be used as hook-shaped fasteners in accordance with the present disclosure.

FIG. 9 is a schematic side view of a cross-section of another device and a method of making tabs that can be used as hook-shaped fasteners in accordance with the present disclosure.

FIG. 10A is a schematic front view and FIG. 10A is a schematic side view of a cross-section of another device and a method of making tabs that can be used as hook-type fasteners according to the present disclosure.

FIG. 11 is a schematic view of the product produced by the method and apparatus of FIG. 10A.

FIG. 12 is a block diagram of an exemplary method for providing hook type fasteners in accordance with the present invention.

FIG. 13 is a schematic side view of a cross-section of another device and a method for making tabs that can be used as hook-like fasteners, wherein between the source of vibrations and the substrate it is possible to introduce discontinuously other materials here.

FIG. 14A-C show sequential schematic cross-sectional views of the device and a method of making tabs that can be used as hook-like fasteners in a discontinuous manner on the thermoplastic object of the present disclosure.

FIG. 15A-C show successive schematic cross-sectional views of another device and a method of making tabs that can be used as hook-like fastener discontinuously in place on a thermoplastic article, according to the present disclosure.

FIG. 16A-C show successive schematic cross-sectional views of another device and a method of making tabs that can be used as hook-like fastener discontinuously in place on a thermoplastic article, according to the present disclosure.

FIG. 17A-C show consecutive schematic cross-sectional views of another device and a method of making tabs that can be used as a hook-like fastening device in a discontinuous manner at a location on a thermoplastic item, according to the present disclosure.

FIG. 18 is an enlarged view of a cross-sectional view of an exemplary tab projecting from a substrate fabricated according to the present disclosure.

FIG. 19 is an enlarged view of a cross-sectional view of an exemplary tab projecting from a layered substrate produced in accordance with an exemplary method of the present invention.

FIG. 20A and 20B are top views of two exemplary masking materials for use in the methods of the present disclosure.

FIG. 21 is a schematic side view of the device cross-section and the method of FIG. 1 for making tabs that can be used as hook-like fasteners, the masking material being connected to the substrate produced according to the present disclosure.

FIG. 22 is a schematic side view of the device cross-section and the method of FIG. 1 for making tabs that can be used as hook-like fasteners, the masking material being used to provide a discontinuous layout of the tabs on the substrate, but the mask is not connected to a substrate made according to the present disclosure.

FIG. 23 is a perspective view of the device of FIG. 21.

FIG. 24 is a schematic side view of the device cross-section and method of FIG. 1 for making tabs that can be used as hook-like fasteners, wherein sealing material is provided to form a discontinuous set of projections on the substrate, the seal surrounding separate regions of the tabs according to the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION [0017] Molded hook fasteners have traditionally been manufactured, for example, by extruding or spraying a thermoplastic melt onto a rotatable drum or mold, which mold contained a layered arrangement or stack of metal plates, the plates having recessed, cut-out or otherwise designed edges providing a longitudinal series of depressions along the outer periphery that may be filled with the polymer melt. It is possible to simultaneously form a basic portion resembling a tape from which projections or hooks formed in these recesses can protrude.

[0018] It has been found that a relatively less complex and relatively less expensive process can use vibration energy to soften the polymer to produce tabs (hooks, mushroom heads, etc.) instead of injection or spraying processes. In one exemplary embodiment, as shown in the schematic cross-sectional side view of FIG. 1, the substrate of thermoplastic material 11 can be placed or passed between the vibrating source 13 and the rotating forming roller 15, the shaft comprising a plurality of hooked or otherwise shaped recesses 17 that are provided along the outer periphery. The substrate 11 may comprise, in the form of a film, sheet, web, composite material, layered material, or may have a different form, which is not limited, or may be parts of the film, sheet, web, a layered or thermoplastic base material, which can be used as separate fastening fasteners, e.g. in a disposable baby diaper. When used in infant diapers, the tactile fastening elements can be attached to a "side fastener" that is used by the user to protect the diaper in the infant. These fasteners may be constructed of a piece of stretchable material to allow for tense stretching and bending after placing the nappy on the infant or when the infant is moving. The present disclosure further contemplates the use of a pre-formed film, sheet, web, composite material, layered material, etc. as the substrate material. in a disposable baby diaper. When used in infant diapers, the tactile fastening elements can be attached to a "side fastener" that is used by the user to protect the diaper in the infant. These fasteners may be constructed of a piece of stretchable material to allow for tense stretching and bending after placing the nappy on the infant or when the infant is moving. The present disclosure further contemplates the use of a pre-formed film, sheet, web, composite material, layered material, etc. as the substrate material. in a disposable baby diaper. When used in infant diapers, the tactile fastening elements can be attached to a "side fastener" that is used by the user to protect the diaper in the infant. These fasteners may be constructed of a piece of stretchable material to allow for tense stretching and bending after placing the nappy on the infant or when the infant is moving. The present disclosure further contemplates the use of a pre-formed film, sheet, web, composite material, layered material, etc. as the substrate material. These fasteners may be constructed of a piece of stretchable material to allow for tense stretching and bending after placing the nappy on the infant or when the infant is moving. The present disclosure further contemplates the use of a pre-formed film, sheet, web, composite material, layered material, etc. as the substrate material. These fasteners may be constructed of a piece of stretchable material to allow for tense stretching and bending after placing the nappy on the infant or when the infant is moving. The present disclosure further contemplates the use of a pre-formed film, sheet, web, composite material, layered material, etc. as the substrate material.

During operation, the vibration source 13 is placed in close proximity to the outer surface of the rotating molding roller 15 and contacting the substrate with a thermoplastic material 11 in the processing. The vibration source 13 may include, for example, a vibrating ultrasonic tube, which is not, however, a limitation. Such tubes may be made of metals such as aluminum or titanium and are sold in the United States by companies such as Ultrasonics, Dukane or Sonitek, and in Europe by a company such as Mecasonics. The source of vibrations may vibrate at frequencies between about 50 Hz to about 50 kHz, as needed. It is possible to use other sources of vibration energy, including a rotating eccentric shaft, sound waves with high pressure or other forms of mechanical and / or electromechanical or acoustic vibration energy, which is not a limitation. Such energy can thus be transferred to the substrate and can facilitate the creation of a protrusion therein.

[0020] A portion of the substrate of thermoplastic material 11 in contact with the forming roller 15 and source 13 of vibrations can be softened by source energy vibrations, and the desired portion of thermoplastic material can be introduced into the formation grooves 17 of the forming roller, when rotated. rollers, hooked or otherwise shaped elements or tabs 19 provided on the face of the film or sheet 21. This process may be referred to as rotational molding. The reference to force can be understood as exerting the required pressure on the thermoplastic material to facilitate its introduction into the recesses and their filling. The thermoplastic sheet 21 may act as a carrier tape for hooks 19.

[0021] Thermoplastic materials that can be used to make hook fasteners may include polyamides, polyolefins, such as polypropylene and polyethylene, butadiene acrylonitrile and styrene (ABS) copolymers, polyester, polycarbonate, polyvinyl chloride (PVC), and mixtures thereof, but without limitation to these materials. Thermoplastic materials can also be modified or reinforced with fillers, fibers, flame retardants, dyes, etc.

An advantage of the present invention is that the thermoplastic material immediately adjacent to the source of vibrations may not melt, thus retaining most or even all of its original properties, i.e. in other words, it is not subjected to a heating process which may cause its deterioration. original properties. [0023] When using previously molecularly oriented material or, alternatively, materials that can be molecularly oriented, it is possible to preserve, increase or reduce the orientation of the particles of material introduced into the recesses, which is accomplished by varying the vibration energy used.

[0024] In FIG. 18 is an enlarged view of a cross-sectional view of an exemplary tab 19 projecting from a substrate 21 manufactured in accordance with an exemplary method of the present disclosure, as shown in FIG. 1. At least partly due to the lower heat transferred to the substrate by the vibrations of the present disclosure compared to other processes in which the temperature of the polymer significantly exceeds the temperatures at which the orientation is destroyed (e.g., Tg in the case of an amorphous polymer or Tm in the case of a crystalline polymer), it is possible to more efficiently maintain and / or even improve the properties of the polymer, which depend on the orientation. The stem portion 19A of the tab formed by the action of the vibration energy can thus substantially maintain its orientation of the particles, and even a small increase is possible, which is measured by shrinkage after forming to shrink before forming. For example, if the polymeric material has a tensile strength (TS) before insertion into the recesses in the direction of the orientation plane that occurs (e.g., in the machine direction, which can be understood, e.g. as extrusion direction) TS1, projections formed by The vibration energy effects may still have a tensile strength (TS2) in the orientation direction of at least 50% TS1 or more (e.g., up to 200%).

Furthermore, if the shrinkage in the orientation prior to exposure to vibration energy has a given value (S1), in a given direction in said substrate, this shrinkage (S2), which may occur after being exposed to vibration energy, in the same direction in the tab it can be at least 50% of the original value or more (for example, 150%). That is, S2> 0.50 (Si). The reference to shrinkage can be understood here as a reduction in the size that will occur when the substrate is heated to a temperature greater than the temperature at which the orientation will be relaxed and substantially disappear. As noted herein, this may be above the glass transition temperature (Tg) for the amorphous polymer or the temperature close to the melting temperature (Tm) for the crystalline polymer.

[0026] Furthermore, the possibility of starting from a substrate that is small or not oriented at all is contemplated, which is to be understood as a situation in which shrinkage in each direction is less than or equal to 5.0%. This can also be characterized as a situation where the tensile strength (ETMD) of the Elmendorf tear in a given machine direction is approximately equal to the tensile strength (ETCD) according to Elmendorf in a given lateral direction, taking into account the given substrate. The transverse direction can be understood as the direction that is transverse to the machine direction (MD). The value of ETMD is therefore different from the ETCD value by +/- 20%.

Elmendorf tear strength can be measured in accordance with ASTM D1922 and can be understood as the average force required to spread the tear along the length of the substrate being tested. In the case of such a substrate that is small or not oriented at all, the use of vibration energy and the formation of the mechanical attachment tab may thus provide a projection that is oriented relative to the essentially devoid of the orientation of the substrate from which it was formed. Orientation in such a protrusion may provide a shrink in a given direction by more than 5.0%. [0027] Furthermore, the possibility of starting from a substrate that has a biaxial orientation is contemplated, which is to be understood as a situation in which there is orientation in the machine direction and towards section. For example, in the direction of the machine and the transverse direction, the shrinkage values ​​can be relatively constant and amount to more than 5.0%. Thus, it can be used that when creating a tab for mechanical hooking, due to the possibility of focusing vibration energy at the surface of the substrate, it is possible to form a tab without substantially destroying the biaxial orientation present in the substrate.

[0028] It should be noted that with respect to the aforementioned properties of the substrate and the tab, one or more of such properties may be present in any given substrate / tab configuration.

[0029] In case it is possible to use a multilayer material (laminate), a part of one or more or layered materials can be formed in the mold cavities, which enables production of a product in which selective selection of the hook part properties is possible. In FIG. 19 is an enlarged view of an exemplary cross-sectional view of an exemplary tab projecting from a layered substrate produced in accordance with an exemplary method of the present disclosure as shown in FIG. 1. Here, the second material 121 has been connected to the substrate material 121 and processing has been made according to the present disclosure. A portion 122 of the second material 121 may extend to the body or cap 19A of the tab 19 and may provide improved properties of the tab. For example, part 122,

[0030] In the case of using a multilayer laminate, the fixing means can be produced in one or more colors, and the tape-like base may have a different color (s). In addition, when using a multi-layer laminate comprising a transparent surface layer, the attachment means or the tape-like material may be formed to be transparent.

[0031] In contrast to prior art methods known in the art, in which the raw material is converted to a molten state prior to forming the web substrate to contain integral tabs, the present disclosure enables the desired properties such as particle orientation, multi-colored layers to be retained or composite structures, by softening the polymer and molding it into a desired shape using vibration energy, which also ensures minimizing the thermal history of the polymer being processed / processed polymers.

[0032] As regards FIG. 1, cooling means can be provided on the forming roller 15 or in its vicinity, and the product formed, the polymer strip 21 comprising a plurality of hooked tabs 19, can be detached from the forming roller. Cooling can be obtained, for example, by external and / or internal cooling of the forming roller, internal and / or external cooling of the vibration source and / or direct and / or indirect cooling of the thermoplastic material using liquid, gas, air or other means.

[0033] In some cases, it is possible to use after the final ultrasonic pulse has cooled down, in order to facilitate the "detachment" of the tabs from the mold or tube. This can be particularly useful in the case where the tabs are formed on the surface of the energy source, i.e. the tube.

[0034] In FIG. 12 shows one example of a method of making projections on a substrate that can be used as one of the cooperating parts in a tactile fastening system. As described in block 100, it is possible to use a forming roll, or other shape, containing a plurality of hollow or shaped shaped recesses that are arranged along the outer periphery of the forming roller and which indentations allow the formation of tabs consistent with the shape of these. recesses. In block 200, it is possible to use a source of vibration energy, for example, an ultrasonic tube or an ultrasonic shaft. It is possible to provide a substrate material (block 300) in the form of, for example, a film, sheet, web, laminate, composite material, etc.,

[0035] A power supply (block 500) may be applied to the source of vibrations to selectively soften the support material and allow the material to be inserted into the recesses in the forming roller to form projections. Alternatively, the forming roller may be smooth, and recesses for forming the tabs may be formed on the surface of the vibration source, as shown in FIG. 5, 7 and 8.

[0036] If desired, the tabs and substrate can be cooled, and the substrate containing projections extending from its surface can be torn off the forming roller to form a tape to be used in the tactile fastening system. Cooling can take place between the forming roller and the source of vibrations, in the forming roller or on the ground, after it has been removed from the roller. The final forming of the tabs can then be carried out to obtain the desired shape.

[0037] As described herein, recesses for forming the tabs may also be formed in the surface of the rotatable tube (see FIGS. 4-8).

[0038] In spite of references to hook-shaped and hook-shaped recesses, it is envisaged that cavities can be selected to provide production of tabs having other shapes that can function as a "hook" part of the tactile fastening system; straight pins, angle pins, conical pins, plugs with mushroom heads and curved pins, as well as elements with varying cross sections, among others such as round, oval, square, rectangular, trapezoidal, cross, multi-lobed, hook-shaped hook, multi-purpose or having a shape that combines these shapes. The tabs may have a solid core or may be hollow, for example, have a tubular shape. Examples of some of these shapes are shown in FIG. 2A - N. For example, in FIG. 2G is an example of a multi-lobed tab, in FIG. 2I illustrates an example of a tubular projection in FIG. 2J is an example of a cross-shaped tongue, in FIG. 2K is an example of a "Y" shaped tab, in FIG. 2L shows an example of a hook hook, and FIG. 2M is an example of a multi-leg protrusion. In FIG. 2J shows an example of a tab with four legs, while in FIG. 2K shows an example of a three-leg projection, wherein a solution is contemplated wherein the tabs may include additional legs, e.g., 5, 6, 7, 8, etc. Such projections may have different heights, thicknesses and protrusion from the carrier tape. 21 or substrate. The tabs can be furthermore formed to have the same height or different heights. 2G is an example of a multi-lobed tab, in FIG. 2I illustrates an example of a tubular projection in FIG. 2J is an example of a cross-shaped tongue, in FIG. 2K is an example of a "Y" shaped tab, in FIG. 2L shows an example of a hook hook, and FIG. 2M is an example of a multi-leg protrusion. In FIG. 2J shows an example of a tab with four legs, while in FIG. 2K shows an example of a three-leg projection, wherein a solution is contemplated wherein the tabs may include additional legs, e.g., 5, 6, 7, 8, etc. Such projections may have different heights, thicknesses and protrusion from the carrier tape. 21 or substrate. The tabs can be furthermore formed to have the same height or different heights. 2G is an example of a multi-lobed tab, in FIG. 2I illustrates an example of a tubular projection in FIG. 2J is an example of a cross-shaped tongue, in FIG. 2K is an example of a "Y" shaped tab, in FIG. 2L shows an example of a hook hook, and FIG. 2M is an example of a multi-leg protrusion. In FIG. 2J shows an example of a tab with four legs, while in FIG. 2K shows an example of a three-leg projection, wherein a solution is contemplated wherein the tabs may include additional legs, e.g., 5, 6, 7, 8, etc. Such projections may have different heights, thicknesses and protrusion from the carrier tape. 21 or substrate. The tabs can be furthermore formed to have the same height or different heights. in FIG. 2J is an example of a cross-shaped tongue, in FIG. 2K is an example of a "Y" shaped tab, in FIG. 2L shows an example of a hook hook, and FIG. 2M is an example of a multi-leg protrusion. In FIG. 2J shows an example of a tab with four legs, while in FIG. 2K shows an example of a three-leg projection, wherein a solution is contemplated wherein the tabs may include additional legs, e.g., 5, 6, 7, 8, etc. Such projections may have different heights, thicknesses and protrusion from the carrier tape. 21 or substrate. The tabs can be furthermore formed to have the same height or different heights. in FIG. 2J is an example of a cross-shaped tongue, in FIG. 2K is an example of a "Y" shaped tab, in FIG. 2L shows an example of a hook hook, and FIG. 2M is an example of a multi-leg protrusion. In FIG. 2J shows an example of a tab with four legs, while in FIG. 2K shows an example of a three-leg projection, wherein a solution is contemplated wherein the tabs may include additional legs, e.g., 5, 6, 7, 8, etc. Such projections may have different heights, thicknesses and protrusion from the carrier tape. 21 or substrate. The tabs can be furthermore formed to have the same height or different heights. and FIG. 2M is an example of a multi-leg protrusion. In FIG. 2J shows an example of a tab with four legs, while in FIG. 2K shows an example of a three-leg projection, wherein a solution is contemplated wherein the tabs may include additional legs, e.g., 5, 6, 7, 8, etc. Such projections may have different heights, thicknesses and protrusion from the carrier tape. 21 or substrate. The tabs can be furthermore formed to have the same height or different heights. and FIG. 2M is an example of a multi-leg protrusion. In FIG. 2J shows an example of a tab with four legs, while in FIG. 2K shows an example of a three-leg projection, wherein a solution is contemplated wherein the tabs may include additional legs, e.g., 5, 6, 7, 8, etc. Such projections may have different heights, thicknesses and protrusion from the carrier tape. 21 or substrate. The tabs can be furthermore formed to have the same height or different heights. the thickness and angle of projection from the carrier tape or substrate. The tabs can be furthermore formed to have the same height or different heights. the thickness and angle of projection from the carrier tape or substrate. The tabs can be furthermore formed to have the same height or different heights.

[0039] The vibration source surfaces 13 may be shaped to extend the time that the thermoplastic materials can be subjected to vibration energy or to otherwise improve the properties and / or performance of the process. In FIG. 3 shows one example of one type of modified surface of the vibrating source 13A in which a portion of the surface 12A of the vibrating source 13A is provided having a shape complementary to the surface of the forming roller 15. FIG. Also, part 12 of the vibrating surface has been modified, in this example as a complex curved surface, to allow passage between the vibrating source 13A and the forming roller 15 of thicker thermoplastic materials 11A.

[0040] In another exemplary embodiment that is shown in FIG. 4, the vibration source may be in the form of a roller, which may include recesses for forming the tabs, and the rotatable shaft 22 may be arranged to press the softened thermoplastic material into these recesses. The rotating vibration source 20 may include a plurality of hook-shaped recesses 17 arranged along its periphery, or otherwise shaped, which may be used instead of the fixed vibration source 13,13A (as shown in FIGS. 1 and 3) and located in close to the rotary shaft 22. The vibration source 20 may be a rotating ultrasonic tube. Such tubes can be made, for example, from titanium and are sold in the United States by Branson Ultrasonics, and in Europe by Mecasonics. The patterned surface roller can be replaced by a smooth roller if a pattern is desired on the rear face 24. The use of a pattern at the back of the product simulating woven leather structures or materials or other patterns may serve to improve the aesthetics of the appearance and / or functionality of the product. In some cases, the surface with the pattern can be designed on one or both rollers so as to create holes in the base material, which makes the fixing element breathable or permeable.

[0041] In another exemplary embodiment that is shown in FIG. 5, a rotational source of vibrations, which as shown in FIG. 4, comprising a plurality of hook-shaped recesses 17 arranged along its outer circumference, or otherwise shaped, may be placed in direct proximity of the non-rotatable fixed platen 26. The pressure plate surface 28 may be smooth or may include a pattern if it is desired to obtain a pattern on the back of the product.

[0042] In FIG. 6 is an exemplary embodiment of a modified fixed platen 30 of another type in combination with a rotatable vibration source. In this example, one surface 32 of the platen was modified, in this example as a complex curved surface, to allow a transition between the vibrating source 20 and the modified pressure plate 30 of thicker thermoplastic materials (substrates). Reference numeral 32A indicates an area in which the surface of the platen 30 has a shape complementary to the shape of the surface of the rotating vibration source.

[0043] In another exemplary embodiment that is shown in FIG. 7, a rotating vibration source 20 comprising a plurality of hook-shaped recesses 17 arranged along its outer circumference 17 or otherwise shaped, may be connected to the rotatable forming roller 15 (as shown in FIG 1) to produce a polymeric tape comprising the tabs on the front and back of sheet 21A. The rotating vibration source 20 may be located in close proximity to the outer surface of the forming roller 15, and the two rollers may include a plurality of hook-shaped recesses 17 arranged along their outer circumferences 17 or otherwise shaped. As shown, this may allow the production of products with hook-shaped elements 19 or other shapes,

[0044] In another exemplary embodiment that is shown in FIG. 8, a rotating vibration source 20 comprising a plurality of hook-shaped recesses 17 arranged along its outer circumference 17 or otherwise formed may be located in the immediate vicinity of another oscillating vibrating source 20A comprising a plurality of hook-shaped recesses 7 spaced along its outer periphery 7 or shaped in another way. This may allow the production of products with hook-shaped elements 19 or otherwise shaped, which are at the same time on the front surface 23 and rear surface 24 of the carrier tape 21A.

[0045] In yet another exemplary embodiment, it is possible to use two or more vibration sources, fixed or rotary, simultaneously. In FIG. 9 shows the use of two fixed sources 13 of vibrations in the immediate vicinity of a rotatable forming roller 15 comprising a plurality of hook-shaped recesses 17 or otherwise shaped, which are arranged along the outer periphery of the forming roll 15.

[0046] As described above, the method and apparatus of the present invention are suitable for forming a product comprising tabs that can function as hook fasteners or protruding elements having other shapes in tactile fastening systems on one or more surfaces of a substrate strip of material thermoplastic, which substrate is in the form of a film, sheet, web, composite material, laminate or other form or parts thereof. The support may have a cellular structure, e.g., a foamed polymer form, or it may be a molecularly oriented film or composite material, which may be, for example, fiber reinforced. The tabs can have different shapes, lengths and dimensions. The tabs can be made of one or more materials forming a multilayer film,

[0047] A solution is contemplated in which at least a portion of the substrate may comprise a thermosetting polymer.

[0048] Furthermore, a solution is contemplated in which the substrate on which the tabs are formed may comprise continuous or discontinuous layers of materials, and combinations thereof. For example, a solution is contemplated in which the tabs can be formed on a discontinuous web to make fasteners in diapers, optionally using a diaper manufacturing device.

[0049] Furthermore, solutions are contemplated in which the tabs may be formed in their final shape or produced as partially shaped and then end-molded to obtain their final shape, for example, the straight pin may be re-shaped to obtain the shape of the hook. or the straight pin can be flattened to obtain a mushroom shape in a subsequent processing step, as well as the deformed hook can be end-formed to obtain a hook that can act as a fastener.

[0050] Further contemplated is a solution in which the protrusions formed in the described manner can be fastening means, temporary or permanent, by engaging in a material comprising loop elements (e.g., structures that provide a mechanical engagement of a tab, such as a hook) or a catch web-like materials, foam-like materials with open cells, or material containing similar or cooperating protrusions (e.g., hooks, plugs, etc.).

A particular advantage of the process described herein is that the projections of the present invention can be formed discontinuously by switching the source / sources of vibration on and off when desired, or by non-uniform change of position and / or contact force and / or frequency. vibration source of vibrations. For example, it is possible to displace the ultrasonic tube or other source of vibrations up and down during the displacement of the web in the process, which is intended to discontinuously form the projections on the substrate. The protrusions can be formed in a desired arrangement, and the system can be changed during processing of the substrate in the production line. The tabs can therefore have the same height or many levels of height, depending on the operating conditions of the device. [0052] The tabs of the present invention may be formed on a substrate such as a web, wherein portions of the formed web are crinkled or pleated to allow the web to stretch. In FIG. FIG. 10A is a schematic front view illustrating an exemplary embodiment of a device configuration in which the forming roller 42 includes a surface portion 44 comprising recesses for producing protruding members and vibrating source 40 and forming roller 42 include complementary configurations configured on their surfaces 46, 46A for forming a creased area. In FIG. 10B is a schematic side view of a cross-section corresponding to the view shown in FIG. 10A. In FIG. 11 is an example of a product, which can be produced using the configuration shown in FIG. 10A. In this example, the hook type elements 19 have been formed on the web 21B in the vicinity of the pleated areas 48. This type of configuration can be attractive when used to form hook elements and crinkle areas on the diaper fasteners, providing elimination of complicated connections fixed with the touch adhesive fastening elements with elastomeric nonwoven, which are currently used in this application. The creased portion and the attachment portion can therefore be formed in the web material simultaneously, whereby a stretchy diaper fastener is formed. Each surface 46, 46A can be configured to provide a creased area, or one of the surfaces may comprise a compliant material such as rubber or elastomer, which under the compressive pressure assumes the shape of the opposite surface. The reference to the wrinkling can be understood as a feature of the web properties achieved by extrusion to obtain a wavy surface such as a web's crease. The reference to a wavy surface can be understood as meaning a surface that rises and falls in the appropriate positions.

[0053] In another exemplary embodiment, the tabs may be formed at the same time as attaching them to a stretchable or to a non-stretchable web. As shown in FIG. 13, a stretchable material or inextensible material 11B can be inserted between the rotatable forming roller 15 and the stationary vibration source 13 (or a rotating vibration source or other form configurations and the vibration sources intended to form the tabs) (see, for example, FIGURES 1, 3 - 9 , 10A and 10B). The vibration source 13 may be located in the immediate vicinity of the mold 15, but far enough to avoid melting or deforming the tensile material or the non-stretchable material 11B.

[0054] It is further possible to form a projection system by moving the pre-perforated or pre-punched masking material between the substrate (foil, sheet, composite material, etc.) and the forming roller so that selective covering of the forming roller regions and the discontinuous spike arrangement are achieved. The mask may be removed (FIG 22) or may be attached to the substrate (FIG 21) if desired. It is therefore possible to change the patterns relatively easily, without having to change the configuration of the forming roller. Punching or creating a mask in a different way can be carried out on the same production line or outside it. [0055] In FIG. 20A and 20B are examples of masking materials used for such purposes. In FIG. 20A is a top view of a mask 80 comprising a sheet of material 82 such as paper, metal, foil, fabric, etc., in which one or more openings 84 are formed. In FIG. 21 shows the device and method of FIG. 1, where a mask 80 in the form of a sheet is introduced into the compression location between the vibrating source 13 and the forming roller 15, whereby the mask parts cover selected recesses 17 and the holes 84 on the surface of the formed substrate 21 form a discontinuous configuration of the tabs 19.

[0056] In FIG. 22 shows a similar process in which the mask 80 can be separated from the substrate 21 and does not become part of the finished product.

[0057] In FIG. 23 is a perspective view of the apparatus and method of FIG. 21. [0058] In FIG. 24 shows another device and method that are similar to those shown in FIG. 1, but the sheet material 90 (such as foam, nonwoven web, etc.) is laminated here with the substrate material 11 and fed to the compression location between the vibration source 13 and the forming roller 15. The molding roller parts 100 can be removed to make it possible for the parts of the material 90 to form a discontinuous set of projections 19 and to allow the material 90A to surround the individual areas in which the tabs 19 are located and to perform the function of sealingpressure. And as shown, a discontinuous pattern-like arrangement 19 is created between the regions of material 90A. The thermoplastic material or layer 11 provides impregnation of the material 90 when forming the protrusions 19. A solution is considered in which the height of the tabs 19 may be smaller than the height of the material 90A so that the tabs do not engage the cooperating element of the fastening system, thereby substantially avoiding premature hook-up. For applications such as diaper closure, it can also protect the child's skin from contact with the tabs.

[0059] Further contemplated is a solution in which the tabs can be formed by holes in the cover layers of the material, which is accomplished by moving a plurality of material layers between the forming roller and the source of vibration, the cover layer can include openings aligned with each other. with arrangements of recesses in one or more rollers, however, it is possible to use openings enabling them to press the substrate material into recesses located in the rollers / rollers or the cover layer can be of sufficiently low strength that the base material can tear covering material and get through to these recesses.

[0060] In FIG. FIG. 20B shows another type of mask 80A made of a porous base material 88 such as a net, non-woven, open-celled foam, etc., which has been coated, e.g., with a coating or by laminating with other material 86 everywhere, except in areas in which the coating holes 84 are formed. The porous material 88 is visible through the openings 84 so that it is possible to produce protrusions through them, whereas the covered areas of the mask prevent the formation of protrusions 19. Moreover, a solution is considered in which the mask can be locally applied directly to a part of the surface a forming roller, for example, by spraying a liquid or by immersing it in a liquid, and then drying it. Such a coating may prevent the formation of protrusions in selected areas of the substrate.

[0061] It is also possible to move between the cooperating rollers / vibration sources (see, for example, FIGS. 7 and 8) of a laminate consisting of a plurality of layers, e.g., a substrate / fabric / thermoplastic fabric, in order to obtain a system. symmetrical protrusions containing a reinforcing layer.

[0062] Further contemplated is a solution in which discrete cuts, slits or other shaped openings may be formed in the substrate, which is effected using elevated portions of the surface of the forming roll (or rotating surface of the tube) providing incisions or very thin portions of the substrate. These substrate modifications can be used to provide a softer and / or stretchable and / or breathable fastening tape.

[0063] The method and apparatus described herein may provide advantages to extrusion / molding processes due to the possibility of less heating and cooling energy consumption, since it is only possible to heat and cool the material used to form the tabs. It is also possible to use many colors by appropriately selecting the substrate material, it is also possible to achieve a wide range of properties by selecting substrate materials including, without limitation, such substrates as molecularly oriented substrates or composite substrates. As substrates can be used materials with printed patterns, logos, etc., where the tabs are created in one or both surfaces, which allows the readability of printed patterns, etc. The process start-up time can be relatively short, and the process can be started and stopped at any time, which eliminates the need for complicated and expensive transfer winders, which is often required for continuous extrusion processes. Finally, it is possible to significantly save the surface of the ground.

[0064] Tactile fasteners are often attached to various thermoplastic objects. One such application includes fixing the tactile fasteners to the car door panels and the interior panels of the roof liner. Materials selected for use as tactile fasteners (polyamides, polyolefins, etc.) often make fixing with the use of glue difficult, as well as being expensive and a frequent source of failure. It is contemplated that a variation of the process and apparatus described herein can provide for eliminating or reducing the need for adhesives for joining fasteners to basic materials, because hook-type fasteners can be formed in the form of parts of such base materials or can be formed on their surface .

[0065] The methods and apparatus described herein mainly relate to continuous or semi-continuous processes for producing tabs on different surfaces. In another exemplary embodiment, which can be termed "immersion molding", the tabs can be formed at any point of the thermoplastic article using automated equipment, a tube supported by a robot or by hand, or another vibration source that can be placed in place, which it is desirable to create tabs. In FIG. 14A, B and C illustrate a method according to which the ultrasound tube 54 may comprise a vibrating surface 50, which may be constructed to include recesses 17 therein (FIGURE 14A). The ultrasound tube 54 can be pressed (arrow A) to the thermoplastic (e.g.

[0066] In some cases, it is possible to use the ultrasound energy after cooling the final pulse, to facilitate the "disengagement" of the tabs from the mold or tube. This can be particularly useful in the case where the tabs are formed in the surface of the energy source, i.e. the tube. A solution is contemplated in which the ending of the tube with the possibility of removal or replacement can be used to ensure the possibility of a relatively rapid change of the projection arrangement.

[0067] In FIG. 15A, B and C a similar solution is shown in which different thermoplastic or thermosetting materials 60 (FIG.15A) can be placed between the ultrasound tube 54 and the object 52, which makes it possible to produce tabs 19 completely or partially from a placed material 60 (FIGURE 15B) . In this way, the tabs 19 can be formed of a second material 60 and using a vibrating process, whereby the material can be combined with the object 52 (FIG. 15C). It is conceivable that this may be particularly useful when the object 52 is a car finishing panel that can be understood as a thermoplastic and / or thermoset door panel, an instrument panel panel, a center console, rear end panels, a roof liner, etc.

[0068] In another exemplary embodiment that is shown in FIG. 16A, B and C, the recesses may be in the mold-like base 56, not in the ultrasound tube 54. The thermoplastic 52 may be placed (FIGURE 16A) and held under pressure (arrows A, FIG. 16B) between the ultrasonic tube and the basis 56 in the form. Vibration energy may be supplied to the tube (FIG 16B), which causes the material 52 to be pushed in from the object 52 into the recesses 17 in the base. Again, the vibration energy supply may then be stopped and the thermoplastic material may be allowed to cool, and the ultrasonic tube may be withdrawn (arrow B, FIG. 16C),

[0069] In FIG. 17A, B and C, it is evident that between the object 52, which requires the formation of protrusions 19 and the mold-like base 56 including recesses 17, it is possible to place various thermoplastic or thermosetting materials 60 (FIG 17A). The tabs can be made of material 60 by pressing together the tubes 54 and molds 56 around the object 52 and material 60 and providing vibrational energy (arrows A, FIG. 17B). Again, the vibration energy supply can then be stopped and the thermoplastic material can be left to cool, and the ultrasonic tube can be retracted (arrows B) (FIGURE 17C),

[0070] The method and apparatus described herein can provide a huge reduction in the complexity of insertion of molded hook-like materials into larger molded articles, since different types of materials can be incorporated into the device layers, and the projections are produced on one or more layers, or by these layers. The materials for the part of the backing layer or for the tabs may therefore differ from the materials forming the substrate. The use of an ultrasonic tube or other source of vibration energy and the use of the form-resembling base disclosed herein for the production of tabs on objects during a continuous or discontinuous process or topical formation of the tabs on the surface of the object may result in lower capital and space requirements, as well as obtaining a very flexible method that can be easily carried. A solution is contemplated in which all of the disclosed properties regarding a continuous or semi-continuous process are also applicable to locally forming the tabs on the object.

[0071] The projections disclosed herein for use as elements in the tactile fastening system can be manufactured in a relatively wide range of dimensions and densities to provide a wide range of attachment or holding strengths. Without being limited to any particular limit values, it is believed that the height of such protrusions can range from less than about 10 microns to more than about 5 mm.

[0072] The description and drawings are intended to illustrate illustratively the embodiments of the invention currently considered to be preferred. The description and drawings are intended to illustrate these embodiments and not to limit the scope of the invention. It will be appreciated by those skilled in the art that other modifications and variations of the present invention may be made in the light of the above teachings, while remaining within the scope of the following claims. Within the scope of the patent claims, it is therefore possible to implement the invention in a different manner from that described and described in the description and drawings.