Method of making a structured surface and article therefrom

European).

EP2582261

HOW TO CREATE A SURFACE WITH A DIFFERENT STRUCTURE AND MANUFACTURE FROM ITS PRODUCT

State of the art

Products with one or more surfaces with different structures are useful in various applications (e.g. abrasive discs, car parts assembly and disposable absorbent products). The articles may be provided as films that exhibit, for example, increased surface area, mechanical fastening structures, or optical properties.

Mechanical fasteners, which are also called hook-and-loop fasteners, usually contain many densely arranged convex protrusions with heads hooking on the loops useful as hook elements, and the loop elements usually contain a lot of woven, non-woven or knitted loops. Mechanical fasteners are useful to ensure detachable attachment in many applications. For example, mechanical fasteners are commonly used in disposable absorbent articles intended to wear such articles around a person's body. In typical configurations, the hook strap or insertion on the attachment tab attached to the back of the waist diaper or clothing for persons not controlling physiological activities, for example, can be attached to the loop material attachment zone in the front waist area, or the hook strap or insertion can be attached to the underlayer ( for example. nonwoven backing) diapers or clothing for people who do not control physiological activities in the front waist area. Mechanical fasteners are also useful in disposable products, such as sanitary towels. The sanitary napkin usually includes a bottom layer which is intended to be positioned near the wearer's underwear. The bottom layer may include hook fasteners for securely attaching the sanitary napkin to underwear that is mechanically hooked onto the hook fastening elements.

The hooks of mechanical fastening systems may be formed into a curved shape or may be substantially vertical projections that are deformed to include, for example, a mushroom-shaped head. Certain methods are available that have varying degrees

EP2582261 versatility and complexity, control the shape of the heads hooking on the loops. See, e.g., U.S. Patent Nos. 3,192,589 (Pearson); 5,953,797 (Provost et al.); 6,132,660 (Kampfer); 6,558,602 (Melbye et al.) And 6,708,378 (Parellada et al.) And US Patent Application Publication

United States, 2002/0124359 (Murasaki et al.). See also U.S. Patent Publication No. 5,749 129.

Hook-and-loop fastening systems can have at least two properties related to breaking strength: peel strength and shear strength. The peel strength corresponds to the force needed to detach the fastening elements from each other by tearing one fastening element up and out from the other fastening element. The shear strength corresponds to the force needed to disengage the fastening elements from each other by pulling at least one of the fastening elements outwards from the other in a plane that is parallel to the fastening elements. Usually the resistance to detachment of the fastening elements is greater at shearing than at peeling.

When the user wants to separate the hook and loop fastening elements (e.g., in an absorbent article such as a diaper), he usually tears the fastening elements apart. The ease with which the fastening elements can be torn off has an impact on the user's perception of the reliability of fastening the fastening elements. For example, if the caregiver removing the diaper from the baby seems to detach the hook strap too easily from the loop attachment zone or backsheet of the diaper, the caregiver may have doubts about the extent to which the fastening elements can keep the diaper closing during use. In some cases, however, low peel strength may cause accidental separation of the fastening elements when wearing the diaper.

Despite the development of the hook and loop fastening technique, it would be desirable to increase the reliability of fastening fasteners, regardless of whether it is real or perceived in nature.

Summary of the Invention

The present disclosure provides a method useful for easily reshaping distal caps on convex elements on a surface with a varied structure. Such further attachments may be, for example,

EP2582261 mechanical fastening caps catching on the loops. This method involves passing the tool between adjacent rows of convex elements so that the tool contacts the protruding parts of at least some of the distal caps. With this method, surfaces with a varied structure can be obtained with convex elements with unique cap shapes. In addition, depending on the initial shape of the convex elements, this method can provide a surface with a differentiated structure, with increased peel strength when hooked on the loop materials relative to comparable surfaces before processing. The present disclosure also provides a fastening laminate and an absorbent article that comprises surfaces with differentiated structure according to and / or made according to the present disclosure.

In one aspect, the present disclosure provides a method of producing surfaces with a varied structure. The method includes providing a thermoplastic substrate with a plurality of rows of convex elements, the convex elements comprising projections with proximal ends attached to the thermoplastic substrate and distal caps, each distal cap having a protruding portion that extends beyond the tab in the first direction. For at least some of the plurality of rows, the tool is moved between two adjacent rows, the tool being in contact with a protruding portion of at least some of the distal caps in two adjacent rows, such that at least a portion of the protruding portion is directed in a second direction other first direction.

In a further aspect, the present disclosure provides surfaces with a varied structure. The surface of varied structure includes a thermoplastic substrate with x and y direction and convex elements with protrusions with proximal ends attached to the thermoplastic substrate and distal caps. Each distal cap has protruding parts that extend beyond the protrusion on all sides, wherein the protruding parts extending beyond the protrusion on all sides are equal in volume and in the case of at least some of the convex elements, protruding parts extending only in one direction x or y are directed downwards towards the thermoplastic substrate.

EP2582261

In some embodiments of the above-mentioned aspects, the surface of the differentiated structure is a mechanical fastener. Accordingly, in other aspects, the present disclosure provides a fixing laminate comprising a support member and a structured surface according to and / or made according to the present disclosure, wherein the thermoplastic substrate has a second surface opposite the convex elements and wherein the second surface of the substrate is connected to a supporting element and an absorbent article containing at least a front waist area, a rear waist area and a longitudinal axis dividing in half the front waist area and the rear waist area, wherein at least one of the front waist area or rear waist area comprises such a fixing laminate.

In a further aspect, the present disclosure provides a device for forming further attachments on convex elements on a surface with a differentiated structure, the device comprising a reference surface with a differentiated structure and a plurality of tools, wherein the reference surface with differentiated structure comprises a reference thermoplastic substrate with multiple rows of convex reference patterns items wherein the reference convex elements comprise protrusions with proximal ends attached to the reference thermoplastic substrate and distal ends, and wherein many tools are sandwiched between multiple rows of reference convex elements on a reference surface of varying structure.

In the present application, singular terms in the English language such as "a", "an" and "the" are not intended to refer solely to a single element, but include a generic class, a specific example of which may be used for illustrative purposes. The English singular terms "a", "an" and "the" are used interchangeably with the terms "at least one". The terms "at least one" and "contain at least one of" followed by a list refer to any one of the items on the list and any combination of two or more items on the list. All numerical ranges include their end values ​​and non-integer values ​​between end values, unless otherwise indicated.

The terms "first" and "second" are used interchangeably. It is understood that, unless otherwise indicated, these terms are used only

EP2582261 in their relative meaning. In particular, in some embodiments, certain elements may be interchangeable and / or in identical multiples (e.g., pairs). For these elements, the terms "first" and "second" may be used for elements only to facilitate orientation in the description of one or more embodiments.

The term "row" refers to many convex elements oriented in a particular direction. A row or row of convex elements can be essentially straight. Each row contains a plurality of spaced-apart convex elements comprising projections with proximal ends attached to the thermoplastic substrate and distal caps.

When talking about the tool passing between two adjacent rows of convex elements, the tool path can be linear (i.e., defined by two points in the line between two rows of convex elements). The path may also be substantially linear, which means that the path may have little curvature or slight oscillation. Some oscillation or curvature may be the result of, for example, continuous strip production processes, which will be understood by one of ordinary skill in the art. Each oscillation or curvature is such that the tool path essentially does not contain a part that crosses the row of hook elements.

The "intersection" of the thermoplastic substrate refers to the intersection of the entire thickness of the substrate.

The term "many" refers to more than one element. In some embodiments, a structured surface, mounting laminate, absorbent article, or method of the present disclosure with multiple rows of convex elements comprises at least 2, 4, 5, 6, 7, 8, 9, 10, 12, 14, 15 or 16 rows of convex elements.

The term "machine direction" (MD) as used above and below means the direction in which the continuous web of thermoplastic substrate is guided during the production of surfaces with different structures. After cutting a surface with a differentiated structure into smaller parts from a continuous web, the machine direction usually corresponds to the y direction of a surface with a differentiated structure. As used herein, the terms machine direction and y direction are commonly used interchangeably. The term "lateral direction" (CD) as used above and below means the direction that is

EP2582261 substantially perpendicular to the machine direction. After cutting the surface with differentiated structure into smaller parts from the continuous web, the transverse direction corresponds to the x direction of the surface with differentiated structure.

It is believed that in some embodiments, partial slits or cuts pass through the thickness of the substrate in a certain percentage range. Percent penetration can be calculated as the depth of the incision divided by the thickness of the substrate, where the quotient is multiplied by 100.

The term "nonwoven" when referring to a sheet or web means a structure of individual fibers or filaments that are interwoven but not identifiable as in knitted fabric. Nonwovens or nonwoven webs can be formed in a variety of processes, such as melt blowing processes, mass molding processes, water needling processes and forming processes of combined carded webs.

The term "elastic" refers to any material that exhibits recovery from stretching or deformation. Similarly, the term "inelastic" refers to any material that does not recover from stretching or deformation.

The "elongation" in percentage refers to {(increased length - initial length) / initial length} multiplied by 100.

The above summary of the present disclosure is not intended to describe each disclosed embodiment or implementation of the present disclosure. The description below provides particularly significant, illustrated embodiments. Therefore, it should be understood that the drawings and description below are for illustrative purposes only and should not be read in a manner that would unnecessarily limit the scope of this disclosure.

Brief description of the drawings

This disclosure can be better understood by considering the following detailed description of various embodiments of the disclosure in conjunction with the accompanying drawings, in which:

FIG. 1A is a top view of an exemplary round distal cap on a convex element before contacting the tool in the method of the present disclosure;

EP2582261

FIG. 1B is a side view of the convex element of FIG. 1A prior to contacting the tool in the method of the present disclosure;

FIG. 1C is a top view of an exemplary round distal cap on a convex element upon contact with a tool in the method of the present disclosure;

FIG. 1D is a side view of the convex element of FIG. 1C upon contact with a tool in the method of the present disclosure;

FIG. 2A is a top view of an exemplary oval distal cap on a convex element prior to contact with the tool in the method of the present disclosure;

FIG. 2B shows a side view of the convex element of FIG. 2 A prior to contacting the tool in the method of the present disclosure;

FIG. 2C is a top view of an exemplary oval distal cap on a convex element upon contact with a tool in the method of the present disclosure;

FIG. 2D shows a side view of the convex element of FIG. 2C upon contact with a tool in the method of the present disclosure;

FIG. 3 is a side view microphotograph of a tool passing between adjacent rows of convex elements according to some embodiments of the method of the present disclosure;

FIG. 4 is a top-view microphotography of a surface of varied structure in contact with many tools with non-aligned tips;

FIG. 5 is a schematic side view of a tool with a conical tip extending between adjacent rows of convex elements according to some embodiments of the method of the present disclosure;

FIG. 6 is a schematic side view of a surface with a varied structure in contact with the tool in the form of a shim according to some embodiments of the method of the present disclosure;

FIG. 7 is a photomicrograph of an exemplary device useful for carrying out the method of the present disclosure;

EP2582261

FIG. 8 A shows a side view microphotograph of multiple rows of convex elements before the tool passes between adjacent rows; and

FIG. 8B is a side view microphotograph of multiple rows of convex elements after the tool has passed between adjacent rows.

Detailed description of the invention

Detailed reference will now be made to embodiments of the disclosure, of which one or more examples are shown in the drawings. The features shown or described in one embodiment may be used in other embodiments to provide a third embodiment. It is to be understood that the present disclosure includes these and other modifications and variations.

FIG. 1A and 2A are top views of some embodiments of the exemplary distal cap 12 on a convex surface member with varying structure prior to contacting the tool in the method of the present disclosure. FIG. 1B and 2B are side views of the embodiments shown in FIGS 1A and 2A. The convex elements have tabs 10 with proximal ends attached to the thermoplastic substrate 14 and distal caps 12. The tab 10 typically has a cross-sectional area that is smaller than the surface area of ​​the distal cap 12. The portion of the distal cap 12 that projects beyond the tab 10 is called the protruding portion. In the illustrated embodiments, the convex elements have protruding parts on all sides of the tabs 10. In some embodiments, the distal cap 12 is round as shown in FIG. 1A, and in some embodiments, a distal cap

12 is oval as shown in FIG. 2A. Other distal attachment shapes are also possible as described below. It is contemplated that the raised parts may be on the first surface of the substrate 14. The first surface of the substrate 14 is the upper surface shown in FIG. 1B and 2B. The surface to which the convex elements are attached may be called the first surface or the first major surface in each of the embodiments disclosed herein. As shown in FIG. 1B and 2B, the protruding parts protrude beyond the tab 10 in at least the first direction. In the embodiment shown, the first direction is a direction substantially parallel to the thermoplastic substrate 14. In other embodiments of convex elements, the direction in

EP2582261 with protruding parts can be tilted at an angle to the thermoplastic substrate. For example, the first direction may deviate from being parallel to the thermoplastic substrate by 5, 10 or 20 degrees.

FIG. 1C and 2C are top views of some embodiments of the exemplary distal cap 12 on a convex surface member of varying structure upon contact with a tool in the method of the present disclosure. FIG. 1D and 2C are side views of the embodiments shown in FIGs 1C and 2C. In the method of the present disclosure, after contacting the tool with the protruding portion of at least some of the distal caps 12 while passing it between two adjacent rows of convex elements, at least a portion of the protruding portion 16 is directed in a second direction different from the first direction. In the illustrated embodiments, the protruding parts 16 which are in contact with the tool are directed downwards towards the thermoplastic substrate 14. The extent to which the protruding parts 16 are deflected from their original direction may depend, for example, on the type and size of the tool, as well as other factors described below. The angle between the second direction and the first direction, which in the embodiment shown is the angle by which at least part of the protruding parts 16 is directed towards the thermoplastic substrate, may be in the range, for example, from 5 degrees to 90 degrees, 10 degrees up to 75 degrees or 20 degrees to 60 degrees. Although in the illustrated embodiments the distal caps 12 have protruding parts on both sides of the caps 10 that are directed in the second direction, it is possible for surfaces with different structure according to and / or made according to the present disclosure to have protruding parts 16 in the other direction only on one side the cap 10, depending on whether the tool is used on both sides of the convex element.

The method of the present disclosure includes passing the tool between two adjacent rows of convex elements. FIG. 3 is a side view microphotograph of a tool passing between adjacent rows of convex elements according to some embodiments of the method of the present disclosure. As shown in the illustrated embodiment, the tool 25 contacts the protruding portion of at least some of the distal caps 12 in two adjacent rows, such that

EP2582261 at least part of the protruding part is directed in a second direction different from the first direction. In the embodiment shown, part of the protruding part is directed towards the thermoplastic substrate.

In the embodiment shown in FIG. 3 tool 25 is a 5 needle. The needle may be made of any preferred material (e.g. metal or polymer). In the embodiment shown, the needle is made of metal. In other embodiments, the tool may be, for example, a wire (e.g., stiff as a needle or more flexible as a guitar string) or a shim made of any preferred material.

Referring now to FIG. 4, a plurality of tools 25 (needles as shown) between a plurality of adjacent rows of convex elements on a thermoplastic substrate 14 are shown. The use of multiple needles allows the distal caps 12 to be shaped simultaneously in multiple rows. Many tools can self-align between multiple rows of convex elements on a thermoplastic substrate 14, which may be possible, for example, due to the narrowing of the needle tips and a certain flexibility of the needles.

Although FIG. 4 shows a series of many tools 25 sandwiched between a plurality of rows of convex elements, such that, for at least part of the thermoplastic substrate 14, the distal caps 12 in each row are in contact on each side, it is not believed that each row of distal the cap 12 requires contact with the tool to create useful surfaces with a varied structure. For example, the tool can be placed between every second row or every third row. In addition, multiple tool groups can be used to process multiple rows of convex elements in one segment or in one zone, while adjacent segments or zones may remain intact by the tools. Alternatively, different sections or zones of convex elements on the thermoplastic substrate 14 may come into contact with tools of different sizes and shapes. Accordingly, the shaping of the further caps 12 on a surface with a varied structure can be adjusted depending on the requirements of the application.

In FIG. At least some of the plurality of tools 25 have different lengths or are otherwise positioned such that their tips are not aligned. This is not required, and in some embodiments, the tool tips may be aligned. In the presented

In an embodiment, when passing multiple tools between multiple rows, each distal cap 12 will be in contact with only one tool at a time, although both sides of the distal caps 12 will be in contact. In this embodiment, it is possible to avoid squeezing the distal caps 12 by contacting both sides at the same time, which may be advantageous for some applications.

In some embodiments, including the embodiments described above, in which the tool is a needle, the tool is narrowed. In FIG. 5 illustrates how a tool with a conical tip can contact distal caps 12 in two adjacent rows of convex elements. The tool 35 contacts the protruding portion 16 that projects beyond the projections 10 of the convex elements. In the embodiment shown in FIG. 5 the tapered part of the tool 35 fits between adjacent rows of convex elements, in contact with the distal caps 12. As shown, the tool 35 does not need to touch the thermoplastic substrate 14 in order to obtain a shaping effect.

In the embodiment shown in FIG. The tool is a 45A or 45B shim, which may be a metal shim, a polymer shim or a shim made of any preferred material and in any preferred shape. If the shim is flexible, many shims passing between multiple rows can self-align between rows of convex elements. In the view shown in FIG. 6 a 45A or 45B shim is passed between the row of convex elements visible to the viewer and the row of convex elements behind the row which is not visible to the viewer. The 45A shim is shown in a position in which it is perpendicular to the thermoplastic substrate 14, with one edge adjacent to or near the thermoplastic substrate 14. The shim 45B is shown in a position in which it is placed at an angle with respect to the thermoplastic substrate 14, with only one corner of the shim 45B passing between adjacent rows of convex elements. Preferred shims that may be useful in carrying out the present disclosure include standard feeler gauges that may be tapered or have parallel sides.

EP2582261

In some embodiments, including the embodiments described above, the tool does not cut the thermoplastic substrate. In some of these embodiments, the tool does not cut the thermoplastic substrate intermittently, so that an interrupted cut is created by the substrate connecting areas. In some embodiments, the tool does not partially cut the surface of the thermoplastic substrate. As mentioned above, the tool does not even have to contact the thermoplastic substrate in some embodiments.

However, in other embodiments, the tool may be a blade (e.g., a rotary knife) that can cut or cut a partially thermoplastic substrate when forming distal caps of the convex elements of the thermoplastic substrate.

In some embodiments, the intermittent cuts are cut in the thermoplastic substrate by a tool (e.g., rotary knife) between some pairs of adjacent rows of convex elements. Intermittent cuts are interrupted by intact areas joining the substrates. Connecting areas are areas where the ground is not cut, and are collinear with the dotted incision. Dotted cuts can be linear in the same direction as many rows. Many parts of the substrate on both sides of the intermittent cuts usually adhere and do not move apart when the rotary knife passes between multiple rows of convex elements . The intermittent cuts may cut across the entire thermoplastic substrate or may partially cut the first face of the thermoplastic substrate (i.e., the same face from which the convex elements protrude) between some pairs of adjacent rows of convex elements. Partial incisions can pass through the thickness of the substrate up to 5, 10, 20, 30, 40, 50, 60, 70, 80 or 90 percent, for example, in the range from 40 to 90 percent. In addition, the thermoplastic substrate in the bonding areas may be undeveloped or there may be partial incisions on the thermoplastic substrate in the bonding areas that do not run through the entire thickness of the substrate and are collinear with the interrupted cuts. Partial cuts can pass through the thickness of the substrate up to 5, 10, 20, 30, 40, 50, 60, 70, 80, or 90 percent. Dotted cuts can be placed between each row of convex elements, every second row

EP2582261 convex elements or in the form of other patterns that can be evenly spaced or unevenly spaced as desired.

For each of these embodiments that include joining areas, the joining areas may be aligned or staggered in a direction perpendicular to the direction of the interrupted cuts. The joining areas may be staggered so that the joining area of ​​one dotted incision is located substantially halfway between the joining areas in an adjacent dotted cut. When the joining areas are staggered in this way, the number of joining areas required to form a surface holder with a diverse structure as an integral whole is kept to a minimum.

In addition, for each of these embodiments that include connecting areas, different lengths of connecting areas may be useful. In some embodiments, all connecting areas between a pair of adjacent rows have a combined length of up to 50 (in some embodiments, 40, 30, 25, 20, 15 or 10) percent of the length of the substrate. In some embodiments, in order to maximize the hook strip's ability to bend, it may be desirable to reduce the total length of these connecting areas to a minimum. Reducing the total length of the joining areas to a minimum can be done by at least one of reducing the length of any particular joining area to a minimum or increasing the distance between the joining areas to a maximum. In some embodiments, the length of one connecting area is up to 3, 2 or 1.5 mm and at least 0.25, 0.5 or 0.75 mm. In some embodiments, the number of joining areas is up to 1.5, 1.25, 1.0, 0.75, 0.60 or 0.5 per cm. The distance between the connecting areas can be, for example, at least 0.75, 1.0, 1.25, 1.5 or 1.75 cm. In addition, the length of the intermittent incision or partial incision between the joining areas can be adjusted and is usually chosen to increase the distance between the joining areas to a maximum. In some embodiments, the length of the intermittent incision or partial incision between the connecting areas is at least 8 (in some embodiments, at least 10, 12, 14, 15, 16, 17, 18, 19 or 20) mm.

In some embodiments, partial incisions are cut in the thermoplastic substrate by a tool (e.g., rotary knife) between

EP2582261 with some pairs of adjacent rows of convex elements. Partial cuts may be linear in the same direction as many rows. Partial incisions can pass through the thickness of the substrate up to 5, 10, 20, 30, 40, 50, 60, 70, 80 or 90 percent, for example, in the range from 40 to 90 percent. When partial incisions pass through the substrate thickness in the range of 40 to 90 percent, the partial incisions allow bending between adjacent rows of convex elements, but the substrate is not easily torn. In some embodiments, the partial incisions pass through the substrate thickness in the range of 50 to 90, 50 to 85, 55 to 85, 60 to 80, or 65 to 80 percent. Partial incisions can be placed between each row of convex elements, every second row of convex elements, or in the form of other patterns that can be evenly spaced or unevenly spaced as needed.

For each of the embodiments where the tool is a blade that provides intermittent cuts or partial cuts in the thermoplastic substrate, the surface of varying structure may be in the form of a roll from which the inserts are cut in a size suitable for the desired application (e.g. for fastening mechanical). Areas connecting intermittent intermittent cuts allow treating surfaces with a diverse structure as an integral whole. Similarly, an integral surface can be treated as a surface with a diverse structure, because partial cuts do not run through the thermoplastic substrate. The connecting areas in each of the embodiments that include them or an uncut part of the substrate in the embodiments comprising partial incisions allow the surface of the differentiated structure to be treated according to and / or produced according to the present disclosure in the form of a roll and transformed as desired.

In some embodiments, full incisions are cut in the thermoplastic substrate (e.g., the entire thickness of the substrate) by a tool (e.g., rotary knife) between some pairs of adjacent rows of convex elements. In these embodiments, a structured surface is usually connected to the carrier as part of the fixing laminate, as described in more detail below. The cuts may run linearly in the direction of the rows and extend from the top edge to the bottom edge of the substrate, creating separate, adjacent strips of thermoplastic substrate on the element

EP2582261 carrier. The cuts can be placed between each row of convex elements, every second row of convex elements or in the form of other patterns that can be evenly spaced or unevenly spaced as needed.

Preferred thermoplastic materials for the substrate and convex elements in the method and surface of the structure disclosed herein include polyolefin homopolymers such as polyethylene and polypropylene, copolymers of ethylene, propylene and / or butylene; ethylene-containing copolymers such as ethylene vinyl acetate and ethylene acrylic acid; polyesters such as polyethylene terephthalate, polyethylene butyrate and polyethylene naphthalate; polyamides such as poly (hexamethylene adipamide); polyurethanes; polycarbonates; poly (vinyl alcohol); ketones such as polyether ether ketone; poly (phenylene sulfide); and mixtures thereof. Usually, the surface of varied structure is made of polyolefin (e.g. polyethylene, polypropylene, polybutylene, ethylene copolymers, propylene copolymers, butylene copolymers and copolymers and mixtures of these substances).

In the method and surface of the structure disclosed herein, the thermoplastic substrate and convex elements are usually an integral part (i.e. formed at the same time as a unitary whole). Convex projections on the substrate can be made, for example, by introducing a thermoplastic material onto a continuously displacing mold surface with inverted-shaped projecting recesses. The thermoplastic material can be passed between a nip formed by two rollers or a nip between the face of the die and the surface of the roller, at least one of the rollers having cavities. The recesses may have an inverted tab shape with a cap with a head hooking on the loops, or may have an inverted tab shape without heads hooking on a loop (e.g., a precursor of the fastening element). In the methods disclosed herein, the term "tab" is intended to include tabs with or without heads engaging with the loops, depending on the embodiment. The pressure exerted by the grip forces the resin into the cavities. In some embodiments, a vacuum can be used to empty the cavities for easier filling of the cavities. The grip is usually wide enough so that a coherent substrate is formed in the cavities. The mold surface and cavities can optionally be cooled by air or water before removing the integrally formed substrate and convex elements from the mold surface, e.g. by means of a roller

EP2582261 astringent. If the tabs formed after exiting the cavities have no heads hooking on the loops, the heads hooking on the loops can then be formed into hooks by the attachment method described in US Patent Nos. 5,077,870 (Melbye et al.) And 5,845,375 (Miller et al. ). Typically, the method of applying the caps involves deforming the tip portions of the convex elements by heat and / or pressure. Heat and pressure, if both are used, can be used sequentially or simultaneously.

Other preferred tool rollers include those formed of a series of plates defining multiple cavities forming projections on their periphery, such as those described, for example, in US Patent No. 4,775,310 (Fischer). Cavities can be formed in tiles, for example, by drilling or photoresist technique. Still other preferred tool rolls may include wire wrapped rolls that are disclosed along with the method of making them, for example, in US Patent No. 6,190,594 (Gorman et al.). Another exemplary method of forming a thermoplastic substrate with convex elements includes the use of a flexible formed strip defining a series of convex-shaped cavities as described in U.S. Patent No. 7,214,334 (Jens et al.). Still other useful methods for forming a thermoplastic substrate with convex protrusions can be found in US Patent Nos. 6,287,665 (Hammer), 7,198,743 (Tuma) and 6,627,133 (Tuma).

Some materials that may be useful precursors to the method of the present disclosure and / or surfaces with differentiated structure according to the present disclosure are commercially available, e.g., from the offer of 3M Company based in St. Paul, under the trade names "CS-600" or "CS-1010".

In the case of the method of the present disclosure in any of its various embodiments, the thickness of the thermoplastic substrate may be up to about 400, 250, 150, 100, 75 or 50 micrometers, depending on the desired application. In some embodiments, the thickness of the thermoplastic substrate is in the range of from 30 to about 225 micrometers, from about 50 to about 200 micrometers, or from about 100 to about 150 micrometers. In some embodiments, the convex elements have a maximum height (above ground) up to 3 mm, 1.5 mm, 1 mm or 0.5

EP2582261 mm, and in some embodiments, a minimum height of at least

0.05 mm, 0.1 mm or 0.2 mm. In some embodiments, the convex elements have a shape ratio (i.e., height to width ratio at the widest point) at least about 2: 1, 3: 1 or 4: 1.

For each embodiment of the method and / or surface with a varied structure according to the present disclosure, multiple rows of convex elements can be evenly spaced. For multiple rows that are evenly spaced, the spacing between multiple rows can vary by up to 10, 5, 2.5, or 1 percent.

In some embodiments of the method for producing a surface with a differentiated structure according to the present disclosure, the convex elements have an initial density of at least 248 per square centimeter (cm²) (1600 per square inch, inch)²). For example, the initial density of convex elements may be at least 394 / cm² (2500 / in²), 550 / cm² (3500 / in²) or at least about 787 / cm² (5000 / in²). In some embodiments, the initial density of the raised elements may be up to about 1575 / cm² (10,000 / in²) or up to around 1182 / cm² (7500 / in²). For example, initial densities in the range of 394 / cm may be useful² (2500 / in²) up to 1575 / cm²(10,000 / in²). However, the spacing between convex elements need not be the same. The initial density of the tabs affects the thickness of the tool, which is useful for transitions between rows of convex elements.

Various shapes of convex elements may be useful in carrying out the present disclosure. The convex elements have distal caps with protruding parts that protrude beyond the tab in the first direction (in the x direction or lateral direction in some embodiments). The protruding portions of the distal caps in the methods and surfaces with a differentiated structure according to the present disclosure are usually "hooking" parts. The term "hooking on loops" as used herein refers to the ability of a convex element on a surface with the diverse structure disclosed herein to mechanically attach to the loop material. The ability of convex elements to attach to loops can be determined and determined using standard woven, non-woven or knitted materials. The area of ​​convex elements with distal caps with protruding parts hooking on the loops will generally provide, in combination

EP2582261 with the loop material, at least one of the higher peel strength, higher dynamic shear strength or higher dynamic friction than the area of ​​the tabs without the heads catching on the loops. Convex elements that have distal caps with "protruding parts hooking on the loops" or "heads hooking on the loops" do not contain ribs that are precursors to hook elements (e.g. elongated ribs, which are extruded in profile, and then cut to form hook elements after stretching towards the ribs). Such ribs will not be able to catch on the loops until they are cut and stretched. Usually, convex elements that have distal caps with protruding parts hooking on the loops have a maximum thickness dimension of up to about 1 (0.9, 0.8, 0.7, 0.6, 0.5 or 0.45 in some embodiments) a millimeter.

Basically, the convex elements with the heads hooking on the loops have a distal cap in a shape that differs from the shape of the tab. For example, the convex element may be mushroom-shaped (e.g., with a round or oval head enlarged relative to the tab), hook, palm, nail, letter T or J. In some embodiments, the thermoplastic substrate has an x ​​direction and a y direction perpendicular to the direction x. In some of these embodiments, at least a portion of the protruding portion extends at a non-zero angle relative to the y direction (machine direction in some embodiments). The non-zero angle can range from 30 to 90 degrees, 50 to 90 degrees, 60 to 90 degrees, 75 to 90 degrees, 80 to 90 degrees or 85 to 90 degrees. In some embodiments, each distal cap has protruding portions engaging with loops extending in multiple (i.e., at least two) directions. In some of these embodiments, the distal caps have protruding portions extending beyond the tabs in both the x and in the y direction. In some embodiments, the distal caps have protruding portions that extend beyond the tabs on all sides. In some embodiments, the convex body prior to treatment as disclosed herein includes a mushroom-shaped head tab (e.g. distal attachments are round or oval before the tool passes between two adjacent rows). The distal attachment can also be angled (e.g. initially in the shape of a square or diamond before the tool passes between two adjacent rows). In some embodiments

EP2582261, the protruding parts protruding beyond the tab on all sides are substantially equal in volume (e.g., such as round or square distal caps). Basically equal in volume means that the volume of the material on all sides of the tab can be the same. As a result of the process of producing convex elements on the substrate described above, some variation may occur, which will be understood by a person having ordinary skill in the art. The volume of material on all sides of the tab may vary, for example, up to about ten (5, 2.5 or 1 in some embodiments) percent and will be considered a substantially equal volume.

The method of the present disclosure includes passing the tool between two adjacent rows of convex elements. At least part of the tool must be sandwiched between at least part of the convex elements in two adjacent rows. Therefore, the device, which is only intended to contact the tops of the distal caps, usually has no part that is actually located between the two distal caps.

In some embodiments, the tool is dragged between adjacent rows of convex elements. In such embodiments, this method usually causes the protruding parts to contact the tool to be directed down towards the thermoplastic substrate. In other embodiments, the tool is pushed between adjacent rows of convex elements. In such embodiments, this method usually causes the protruding parts to contact the tool to be directed upward from the thermoplastic substrate. In some embodiments, the tool is stationary and the thermoplastic substrate stretches under the tool. Depending on whether dragging the thermoplastic substrate causes more up or down movement relative to the distal attachments, the protruding parts that are in contact with the tool can be directed outwardly from the thermoplastic substrate, or down towards the thermoplastic substrate, respectively.

In addition to the specific embodiments described above, the tool may have any preferred shape as long as it fits between two adjacent rows of convex elements. The tool may be, for example, a wire or needle with a circular cross-section (e.g., such as a guitar string) or a non-circular cross-section. The tool is usually large enough (i.e., of sufficient thickness or diameter) to come into contact with protruding parts

EP2582261 distal caps without excessive pressure on the tabs. The maximum thickness or diameter of the tool may be the distance between the tabs, which is usually larger closer to the distal attachment than to the proximal end attached to the thermoplastic substrate. The method of the present disclosure is useful at different mandrel densities (convex component density) because, for example, the diameter or thickness of the tool or tools can be selected to suit different mandrel densities. Wires of various thicknesses or diameters can be selected depending on, for example, the distance between the tabs in multiple rows, the size of the distal caps, the distance between the distal caps and the desired degree of deflection of the cap in the other direction (towards the ground in some embodiments). For example, the E guitar string can be useful when the density of raised elements is 550 / cm²(3500 / in²). In the case of increased spacing between multiple lines, various B or G guitar strings can be useful. Similarly, various feeler gauges or needles of different sizes can be selected for different surfaces with different structures.

The tool usually has sufficient strength to avoid bending when pressed against a thermoplastic substrate, but preferably has some ease of positioning between rows without destroying the convex element. The flexibility of the tools usually allows them to remain in place between adjacent rows, even when there is some variation in row spacing across the web of workpiece. Due to this phenomenon, many of the tools used between multiple rows can be considered self-adjusting, which can increase the stability and repeatability of this method.

The tool can be held perpendicular to the thermoplastic substrate as it passes between two adjacent rows, but is usually at an angle in the range of 0 ° to 90 ° relative to the thermoplastic substrate. In some embodiments, the tool is at an angle of 10 degrees to 60 degrees relative to the thermoplastic substrate. In some embodiments, the tool is set at an angle of 15 degrees to 45 degrees relative to the thermoplastic substrate. Similarly, the pressure used to hold the tool down while dragging under it

EP2582261 thermoplastic substrate, or pulling it through the convex elements, may vary. The pressure should be sufficient to keep the tool in contact with the distal attachments. When using multiple tools in the method of the present disclosure, the length of the individual tools can be selected to provide the desired degree of ease of self-alignment and process stability, without too long a period of time allowing the needles or wires to easily move or cross each other. For wires or needles with a smaller diameter, this length can be advantageously shortened to provide the desired stiffness for the individual needles or wires. As shown above in FIG. 4, it is believed that the length of individual needles or wires need not be the same length. In addition, it is believed that the tool may be similar to a wire, but with a tip that has a different shape useful for shaping the protruding parts of distal caps.

In embodiments where the tool is a needle (e.g., a hypodermic needle), including those embodiments described above and shown in FIG. 3 and 4, the needle may further be useful for blowing cold air onto a thermoplastic substrate to compensate for the heat generated by friction of the needles against the protruding parts of the distal caps. In other embodiments, the needles may be useful for delivering pigment or glue drops, for example, for a particular intended use.

In some embodiments of the method of the present disclosure, the tool is a cutting blade (e.g., a rotary cutting blade). In these embodiments, in addition to shaping the further attachments, the tool creates cuts in the thermoplastic substrate. Intermittent cuts can be made, for example, by means of rotary cutting blades with slots to form connecting areas. The height of the blade in the slots can be adjusted to allow partial cutting or to prevent cutting at all, depending on the desired embodiment. Partial incisions can be made, for example, by adjusting the height of the rotary die blades to create incisions of the desired depth. In the case of intermittent or uninterrupted cuts across the entire thickness of the thermoplastic substrate, cutting can be performed on any surface of the continuous web, surfaces with convex elements, or the opposite surface. Usually, however, in the case of cuts on the thickness of the thermoplastic substrate, these cuts are made on the same

EP2582261 surface from which convex elements protrude. Similarly, in the case of partial incisions, these incisions are made on the same surface from which the convex elements protrude. It is to be understood that the rotational methods of cutting on a continuous web disclosed herein may in some cases result in cuts that cross or intersect with a row of convex elements. Although the rotary matrix, for example, may be positioned to form an incision between rows of convex elements, the variability of the web production process and the rotational rigidity of the rotary matrix may cause the incision to intersect with the row of convex elements and then return to its final position.

The method of the present disclosure in each of its embodiments can be repeated several times (e.g., two or more times) to obtain the desired results. In such cases, the size and shape of the tools used in the first and subsequent applications of this method may be different if desired. In addition, in some embodiments, the thermoplastic substrate has an upper edge and a lower edge, and the tool transfer between two adjacent rows of convex elements can be started at the upper edge and continue to the lower edge or any part of the thermoplastic substrate between them.

The method of the present disclosure can provide surfaces of varying structure with convex elements with distal caps of a unique shape. In some embodiments, the thermoplastic substrate has an x ​​direction and a y direction perpendicular to the x direction, the distal caps having protruding portions extending beyond the tab in both the x direction and the y direction, and the protruding portions extending in only one x direction or y direction are directed in the other direction. In FIG. 8A shows a photomicrograph of convex elements in the starting material before applying the method of the present disclosure, and FIG. 8B shows raised parts after processing. In some embodiments, the thermoplastic substrate is a web of indefinite length having a machine direction and a transverse direction.

In embodiments where the thermoplastic substrate moves in the machine direction or the tool only moves in the machine direction between the rows of convex elements, in the second direction only the protruding parts extending in the transverse direction are directed.

EP2582261

Other ways of forming further caps of convex elements on a surface of varying structure are known. For example, passing the convex elements through the slit of the heated rubber roller and thrust roller causes the protruding portions of the distal cap that protrude beyond the protrusion downward toward the ground. This method is described in US Patent No. 6,132,660 (Kampfer). However, the rubber roller can wear out, which causes changes in the process. Furthermore, this process can be limited by speed and is limited by the degree to which the shape of the distal cap can be changed.

In contrast, the method of the present disclosure does not require the use of rubber, which can deteriorate quickly, and is easy to make. In addition, the size and shape of the tool can be adjusted to achieve the versatility of shaping further attachments.

Structured surfaces according to and / or produced according to the methods described herein may have a greater peel strength when hooked onto the loop material than a comparable surface with a structured structure that is not treated. A comparable surface with differentiated structure is "the same" as the structure with differentiated surface disclosed herein, except that it has not been subjected to the method of the present disclosure. A comparable surface with a varied structure has the same dimensions (e.g. length, width and thickness), the same density and height of convex elements, the same dimensions of protrusions, the same configuration of convex elements (e.g. rows) and is made of the same material as the surface of varying structure according to the present disclosure. As shown in the examples below, the results may depend on the loop material used and the output shape of the distal caps; however, the peel strength is generally increased by the methods described herein. In some embodiments, the increase in peel strength in the y direction or in the machine direction is most pronounced.

Structured surfaces according to some embodiments of the present disclosure have distal caps, each distal cap having protruding portions that extend beyond the tab on all sides, and the protruding portions extending beyond the tab on all sides

EP2582261 are substantially uniform in volume and wherein, in at least some of the convex elements, the projecting parts extending in only one x direction or y direction are directed down towards the thermoplastic substrate. Usually the convex elements are arranged in rows on a thermoplastic substrate. In these embodiments, the term "substantially equal in volume" has the same meaning as described above with respect to the starting material. The starting material may have, for example, a round distal cap. The distal cap on a surface with a varied structure obtained from such a starting material will have protruding parts, some downward and some not rounded. In some embodiments of a surface with a varied structure, the thermoplastic substrate is a web of indeterminate length having a machine direction and a transverse direction, where the y direction is the machine direction, where the x direction is the transverse direction, and only the protruding parts extending in the transverse direction are directed in down towards the thermoplastic substrate.

In some embodiments of the method disclosed herein, a plurality of tools are placed in a device comprising a reference surface with a differentiated structure, wherein the reference surface with a differentiated structure includes a reference thermoplastic substrate with multiple rows of reference convex elements, wherein the reference convex elements comprise protrusions with proximal ends attached to the reference thermoplastic substrate and distal ends, and wherein many tools are sandwiched between multiple rows of reference convex elements on a reference surface of varying structure. In some embodiments of this device, the tools include at least one of needles, wires or shims. Typically, in such instruments, these tools are positioned to extend from the tool at a distance advantageous to carry out the method disclosed herein.

One example of an apparatus for carrying out the method described herein is shown in FIG. 7. In FIG. 7, a series of hypodermic needles 125 were assembled to obtain the desired spacing to align with the desired surface of varying structure. The desired distance can be

EP2582261 can be obtained, for example, by placing needles in rows of a spline web (not shown), which may be identical to the surface of the differentiated structure to be treated, except that there are no further caps on the tabs. The web with tabs can be attached to a piece of rubber with a double-sided adhesive tape (not shown), and after placing the needles 125 a second piece of rubber 105 is positioned behind them and the assembly is placed in clamp 100. The number of needles 125 can be adjusted to apply this method to the desired width of the surface with varying structure to be treated. After grasping the device by the handle 115, the method of the present disclosure can be manually applied to surfaces of varying structure. Needle length 125 can be adjusted as described above. For example, the needles may protrude from a piece of rubber 105 by 0.5 cm to 5 cm, in some embodiments by 1 cm to 3 cm or 1.5 cm to 2.5 cm.

Other ways to set tools are possible. For example, a reference surface with a varied structure may have convex edges or ridges on a thermoplastic substrate. Such a structured surface can be produced, for example, by extruding a profile (e.g., by a method similar to that described in U.S. Patent No. 4,894,060 (Nestegard). Tools can be placed between edges or ridges.

Preferably, the method of the present disclosure does not require that the tool, convex elements or thermoplastic substrate be heated. It is surprising that the method of the present disclosure causes permanent deformation of the contacting protruding parts of the distal caps, even in the absence of external heating. Although external heating is not required, in some embodiments it may be desirable to heat the tool and / or the thermoplastic substrate. In some embodiments, it may be useful to apply the method of the present disclosure while the distal caps are still warm after performing the cap application step that uses heat and pressure (e.g., as described in US Patent Nos. 5,077,870 (Melbye et al. .) and 5,845,375 (Miller et al.)).

EP2582261

In embodiments where the distal attachments are heated before or during contact with the tool, the heating is usually carried out below the melting point of the distal attachments. When the thermoplastic material used to form the convex elements is a copolymer (e.g., copolymers of ethylene and propylene), the further caps may have more than one melting point. In these embodiments, the term "below the melting point of the further attachments" means below at least one of the melting points. Heating of the thermoplastic web may be carried out, for example, in a heated chamber such as an oven, or infrared radiation or hot air treatment may be used. In some embodiments, a structured surface may be heated in the range of 40 ° C to 80 ° C (50 ° C to 60 ° C in some embodiments) prior to contact with the tool. In embodiments where the tools are needles, hot air may be introduced through the needles to heat the tool and / or the surface with a different structure when the distal tool caps come into contact. In other embodiments, the tools may be heated wires or heated shims.

In some embodiments, the method of the present disclosure includes stretching the thermoplastic substrate in at least one direction. Stretching may be most beneficial when the other attachments touch the tool or tools. Stretching can also be done before the distal attachments contact the tool or tools, but as a result of stretching the variation in row spacing may increase.

Stretching the thermoplastic substrate with convex elements can be useful, for example, to reduce the cost of the resulting surface with a varied structure, which can be a mechanical fastening. However, there is also the possibility of reduced performance due to a limited number of convex elements (e.g. hook elements) per unit of area. The method of the present disclosure may be useful, for example, to balance the potential loss of performance as a result of lowering the density of convex elements by increasing the percentage density of the convex elements that can attach to the loop fibers, and / or increasing the peel strength of each such attachment. In addition, start with a higher mandrel density (density of raised parts) before stretching

EP2582261 will mean that the density of convex elements after stretching can be comparable with traditional mechanical fasteners. For example, when the density of convex elements is 550 / cm² (3500 / in²), stretching to a ratio of about 2: 1 results in a density of convex elements of about 248 / cm² (1600 / in²), which is a traditional mandrel density for mechanical fasteners. Stretching of the thermoplastic substrate with convex elements ensures orientation of the particles caused by stretching in at least the substrate.

In embodiments where the thermoplastic substrate is stretched, the stretching can be carried out on the web biaxially or uniaxially using techniques known in the art. When the thermoplastic substrate is, for example, a web of indeterminate length, uniaxial stretching in the machine direction can be performed by propelling the thermoplastic web on rolls at increasing speed. The most versatile stretching method that allows uniaxial, sequential biaxial and simultaneous biaxial stretching of a thermoplastic web uses a smooth film dilator. Such a device grips the thermoplastic web with a plurality of clamps, grippers or other elements for gripping the edges of the film by the opposite edges of the thermoplastic web in such a way that uniaxial, sequential biaxial or simultaneous biaxial stretching in the desired direction is obtained by propelling the gripping elements at different speeds along divergent guides. Increasing the machine direction crimping speed generally results in machine direction stretching. Elements such as diverging guides generally cause lateral stretching. Uniaxial and biaxial stretching can be achieved, for example, by the methods and disclosed in US Patent Application Publication No. 2005/0202205 (Petersen et al.) And references cited herein. Smooth film stretchers are available on the market, for example, from Bmckner Maschinenbau GmbH based in Siegsdorf, Germany.

In some embodiments, stretching increases at least one of the length or width of the thermoplastic substrate by at least 1.5 times (at least 2, 2.5, or 3 times in some embodiments). In some embodiments, stretching increases both the length and width of the thermoplastic substrate by at least 1.5 times (at least 2, 2.5

EP2582261 or 3 times in some embodiments). In some embodiments, stretching increases at least one of the length or width of the thermoplastic substrate up to 10-fold (up to 7 or 5-fold in some embodiments). In some embodiments, stretching increases both the length and width of the thermoplastic substrate by up to 10 times (up to 7 or 5 times in some embodiments).

The stretching can be adjusted to increase the desired product properties to the maximum (e.g. hooking with the desired loop). In some embodiments, the stretching is carried out at least to the actual stretch ratio. When thermoplastic film (e.g. the thermoplastic substrate described herein) is uniaxially or biaxially stretched at a temperature below the melting point of the thermoplastic material, in particular at a temperature below the linear stretching temperature of the film, the thermoplastic film can stretch unevenly and a clear boundary forms between stretched and unstretched parts. This phenomenon is defined as necking or linear drawing. In general, however, the entire thermoplastic substrate is stretched evenly when it is stretched to a sufficiently high degree. The stretch ratio at which this occurs is referred to as the "actual stretch ratio" or "actual pull ratio". The actual stretching ratio can be determined, for example, as the stretching ratio at which the relative standard deviation of the local stretching ratio measured at different places on the thermoplastic substrate is less than about 15 percent. It is understood that stretching above the actual stretching ratio provides much more uniform properties or characteristics such as thickness, tensile strength and modulus of elasticity. For any given thermoplastic substrate and stretching conditions, the actual stretching ratio depends, for example, on factors such as the composition of the thermoplastic resin forming the thermoplastic substrate, the morphology of the thermoplastic substrate formed due to the rapid cooling conditions on the tool roll and the temperature and speed of stretching. In addition, for biaxially stretched thermoplastic substrates, the actual stretching ratio in one direction will be affected by the stretching conditions, including the final ratio

EP2582261 stretching in the other direction. Therefore, the actual stretch ratio can be considered to occur in one direction, taking into account the constant stretch ratio in the other, or, alternatively, there can be a pair of stretch ratios (one in the first direction and one in the other), which results in real stretch ratio. The term "stretch coefficient" refers to the coefficient of the linear dimension of a given portion of a thermoplastic substrate after stretching to the linear dimension of the same fragment before stretching.

In some embodiments, stretching is performed at elevated temperatures. This may allow an increase in the elasticity of the thermoplastic substrate during stretching. Heating can be provided, for example, by infrared radiation, hot air treatment or by stretching in a heat chamber. In some embodiments, the heat is applied only to the second surface of the thermoplastic substrate (i.e. opposite the surface from which the convex elements protrude) to minimize any damage to the tabs with attachments that may arise due to heating. For example, in these embodiments, only the rolls that are in contact with the second surface of the thermoplastic substrate are heated.

After stretching, the thickness of the thermoplastic substrate is reduced such that the ratio of the thickness of the thermoplastic substrate before stretching to the thickness of the thermoplastic substrate after stretching can be, for example, from 2: 1 or 3: 1 to 10: 1, from 5: 1 to 10: 1 in some embodiments. The thickness of the thermoplastic substrate may be, for example, in the range from 5 to 200 μm, 10 to 100 μm or 30 to 70 μm.

After stretching, the final density of the convex elements is lower than the initial density of the convex elements. In some embodiments of the method for producing a surface with a differentiated structure according to the present disclosure, the convex elements have a final density (i.e., after stretching) of at least 20 / cm² (129 / in²), 40 / cm² (258 / in²), 60 / cm² (387 / in²), 75 / cm² (484 / in²), 100 / cm² (645 / in²) or 124 / cm² (800 / in²). For example, the final density of convex elements may be at least 248 / cm² (1600 / in²) or at least about 394 / cm² (2500 / in²). In some embodiments, the final density of the convex elements may be up to 787 / cm² (5000 / in²)

EP2582261 or up to about 1182 / cm² (7500 / in²). For example, final densities ranging from 124 / cm may be useful² (800 / in²) up to 1182 cm² (7500 / in²), 124 / cm²(800 / in²) up to 787 / cm² (5000 / in²) and 124 / cm² (800 / in²) up to 394 / cm² (2500 / in²). Again, the spacing between convex elements need not be the same.

For each of the embodiments of methods for producing a surface with a differentiated structure or surface with a differentiated structure disclosed herein, the thermoplastic substrate may be in the form of a roll from which surface inserts of varying structure (e.g., mechanical fastener inserts) can be cut in a suitable size for the desired application. In this application, the thermoplastic substrate may also be an inset that has been cut to the desired size. In some of these embodiments, the second surface of the thermoplastic substrate (i.e., the surface opposite the first surface from which the convex elements protrude) may be covered with glue (e.g., pressure sensitive adhesive). In such embodiments, when the thermoplastic substrate is in the form of a roll, a release liner for exposed adhesive may be used.

In some embodiments of the method for manufacturing a surface with the varied structure disclosed herein, the thermoplastic substrate is not connected to the carrier, at least when pre-formed.

When the substrate is not attached to the carrier, it may mean that the substrate is not laminated (e.g. laminated by extrusion), glued, connected (e.g. ultrasonically connected or pressed by pressure) or otherwise attached to the carrier (e.g. ground, fastening tab, fastening tape etc.). In other embodiments, the method further includes joining the second surface of the thermoplastic substrate (i.e. opposite the first surface from which the convex elements protrude) with the supporting element. The thermoplastic substrate may be attached to the support element, for example, by lamination (e.g. extrusion lamination), adhesives (e.g. pressure sensitive adhesives) or other joining methods (e.g. ultrasonic joining, pressure joining or surface joining). These joining methods can be carried out before the protruding parts of the distal attachments contact the tool, after the protruding parts of the distal attachments contact the tool, or before or after possibly stretching the thermoplastic substrate, as required. Thermoplastic substrate

EP2582261 can be connected to the carrier element when forming a thermoplastic substrate with convex protrusions. In embodiments where the method involves cutting a thermoplastic substrate before the substrate is attached to the carrier with a pressure sensitive adhesive, the viscosity of the pressure sensitive adhesive may be selected so that it does not pass through the cuts during the joining process. The product obtained by joining surfaces of differentiated structure to the support element may be a fastening laminate, for example, a fastening tab connected to the bottom layer of the absorbent article useful for connecting the front waist area and the rear waist area of ​​the absorbent product.

The support element can be continuous (i.e. without through holes) or discontinuous (e.g. including holes or perforations). The support element may contain a number of preferred materials, including woven webs, nonwoven webs (e.g., webs formed from mass, webs obtained by water needling, pneumatically laid webs, meltblown webs and combined carded webs), textile products, plastic foils artificial (e.g. monolayer or multilayer films, coextruded films, transverse laminated films or films containing foam layers), and combinations thereof. In some embodiments, the carrier is a fibrous material (e.g.

woven, non-woven or knitted material). In some embodiments, the carrier includes a plurality of layers of nonwoven materials, for example, at least one layer of meltblown nonwoven and at least one layer of mass formed nonwoven or any other preferred combination of nonwoven materials. For example, the carrier may be a multilayer melt-blow molded, melt-molded, melt-molded, or melt-blown melt-blow. Optionally, the support element can be a composite web comprising a nonwoven layer and a dense film layer.

Fibrous materials that provide useful support elements can be made of natural fibers (e.g., wood or cotton fibers), synthetic fibers (e.g. thermoplastic fibers), or a combination of natural and synthetic fibers. Exemplary materials for forming thermoplastic fibers include polyolefins (e.g., polyethylene,

EP2582261 polypropylene, polybutylene, ethylene copolymers, propylene copolymers, butylene copolymers and copolymers and blends of these polymers), polyesters and polyamides. The fibers may also be multi-component fibers, for example, with a core of one thermoplastic material and a sheath of another thermoplastic material.

Useful support elements can have any preferred basis weight or thickness that is desired for a particular application. In the case of a fibrous support, the basis weight may range, e.g. from at least about 20, 30 or 40 grams per square meter, up to about

400, 200 or 100 grams per square meter. The support element may be up to about 5 mm, about 2 mm or about 1 mm thick, and / or at least about 0.1, about 0.2 or about 0.5 mm thick.

One or more zones of the support member may include one or more elastically stretchable materials extending in at least one direction after the application of force and returning approximately to their original dimension after the force has ceased. However, in some embodiments, including embodiments in which the tool crosses the thermoplastic substrate, at least a portion of the carrier connected to the second face of the substrate is not stretchable. In some embodiments, a portion of the carrier connected to the second surface of the substrate will have an elongation up to 10 (up to 9, 8, 7, 6 or 5 in some embodiments) in a transverse direction perpendicular to the cuts in the substrate.

A fixing laminate, which can be formed after the thermoplastic substrate has been connected to the support element, may be useful, for example, in absorbent articles. Exemplary absorbent articles have at least one front waist area, rear waist area, and a longitudinal axis dividing the front waist area and rear waist area in half, wherein at least one of the front waist area or rear waist area comprises a surface of varying structure produced according to the method disclosed in this description. The fastening laminate may be in the form of a fastening fold that is connected to at least one of the front waist area or rear waist area extending outward from at least one of the left longitudinal or right edges

EP2582261 longitudinal edge of an absorbent article. In other embodiments, the attachment laminate may form an integral part of the absorbent article's ear.

The fastening laminates for use in absorbent articles can have any useful shape and size. The fastening tab may have an end intended for a manufacturer that is attached to a disposable absorbent article (i.e., an end that is permanently attached to the absorbent article, usually in the waist area), and an end intended for a user who is away from the attachment site ( i.e. the end that is gripped by the user). In some embodiments, the end intended for the user may be narrower than the end intended for the manufacturer. In these and other embodiments, it may be useful to treat the convex elements at different locations of the fastening tab in a variety of ways. For example, tools can be moved between each row at the end intended for the user, while in the production direction there can be multiple rows between tools. Such a fit can be particularly advantageous, for example, to increase the peel strength on the narrower edge on which there are less convex elements hooking on the loop.

For, for example, disposable products, such as sanitary towels, fixing laminate may also be useful. The sanitary napkin usually includes a bottom layer which is intended to be positioned near the wearer's underwear. The bottom layer may comprise a thermoplastic substrate with convex elements for securely attaching the sanitary napkin to the undergarment, which mechanically engages with further attachments.

In some embodiments of absorbent articles according to the present disclosure (e.g., diapers or other clothing articles for persons not controlling physiological functions), the article further comprises a loop material that engages on the surface of the differentiated structure disclosed herein. The loop material may be provided, for example, as the bottom layer of absorbent articles, optionally the loop inserts may be provided as attachment zones in the front waist area or back waist area. The loop may be made of any preferred material that engages with appropriate hook fasteners. In some embodiments, the loop material is

EP2582261 knitted, woven or non-woven fabric. For example, the fiber loops may protrude from a knitted, woven or non-woven backing, or they may be loops with extrusion-connected fibers, glued and / or sound-connected. Preferred loop materials available on the market include knitted and extrusion loop materials from the 3M Company based in St. Paul, Minnesota. In some embodiments, the absorbent article of the present disclosure comprises an extrusion loop. In some embodiments, the absorbent article of the present disclosure comprises a nonwoven loop.

In some embodiments, in which the carrier is a fibrous web, the coupling involves hitting a heated gaseous fluid (e.g. ambient air, dried air, nitrogen, inert gas or other gas mixture) into the first surface of the fibrous web during its displacement; striking the heated fluid on the second surface of the substrate while the continuous web is moving, the second surface being opposite the first surface of the substrate; and contacting the first surface of the fibrous web with a second surface of the substrate such that the first surface of the fibrous web is melted (e.g., surface connected or joined with a fluff retaining bond) to the second surface of the substrate. Impact of the heated gas fluid on the first surface of the fibrous web and impact of the heated gas fluid on the second surface of the substrate can be carried out in turn or simultaneously. The term "surface bonded" when referring to the joining of fibrous materials means that parts of the surface of the fibers among at least part of the fibers are joined in a molten state to the second surface of the substrate in front of the convex elements in such a way as to substantially retain the original (before joining) shape of the other the surface of the substrate and to substantially keep at least some parts of the second surface of the substrate in an exposed state, on a surface-joined surface. In quantitative terms, surface-bound fibers can be distinguished from embedded fibers in that at least about 65% of the surface area of ​​the surface-linked fibers is visible above the second surface of the substrate in the joined portion of the fiber. It may be necessary to inspect from more than one angle to illustrate the entire field

EP2582261 fiber surface. The term "fluff retaining bond" when referring to fibrous bonding means that the fibrous bonded material has a fluffiness that is at least 80% of the fluffiness exhibited by that material before or in the absence of the bonding process.

The fluffiness of fibrous material as used herein means the ratio of the total volume occupied by the web (including fibers, as well as interstitial spaces in the material that are not occupied by fibers) to the volume occupied by the material of the fibers themselves. If only part of the fibrous web has a second substrate surface attached thereto, retained fluffiness can easily be determined by comparing the fluffiness of the fibrous web in the joined area with the fluffiness of the web in the non-joined area. Under some conditions, it may be convenient to compare the fluffiness of the bonded web with the fluffiness of a sample of the same web before bonding, for example, if the entire fibrous web has a second substrate surface attached to it.

Further methods and apparatus for connecting a continuous web to a fibrous support web by means of a heated gaseous fluid can be found in US Patent Application Serial Numbers 12 / 974,536 and 12 / 974,329, pending at the same time, both filed December 21, 2010, published as US 2011151171 and US 2011147475.

Selected embodiments of the disclosure

In a first aspect, the present disclosure provides a method of producing surfaces with a varied structure, the method comprising:

providing a thermoplastic substrate with a plurality of rows of convex elements, the convex elements comprising projections with proximal ends attached to the thermoplastic substrate and distal caps, each distal cap having a protruding portion that extends beyond the tab in the first direction; and for at least some of the plurality of rows, passing the tool between two adjacent rows, the tool being in contact with the protruding portion of at least some of the distal caps in two adjacent rows, such that at least a portion of the protruding portion is directed in a second direction other than first direction.

EP2582261

In a second embodiment, the present disclosure provides a method according to a first embodiment, wherein the tool does not cut the thermoplastic substrate.

In a third embodiment, the present disclosure provides a method according to the first or second embodiment, wherein the tool is a needle, wire or shim.

In a fourth embodiment, the present disclosure provides a method according to any one of the first to third embodiments, wherein the tool is narrowed.

In a fifth embodiment, the present disclosure provides a method according to any one of the first to fourth embodiments, further comprising stretching the thermoplastic substrate in at least one direction.

In a sixth embodiment, the present disclosure provides a method according to the first embodiment, wherein the tool is a rotary knife.

In a seventh embodiment, the present disclosure provides a method according to any one of the first to sixth embodiments, further comprising heating at least one of the tool or convex elements.

In an eighth embodiment, the present disclosure provides a method according to any one of the first to sixth embodiments, the method not including heating the tool or convex elements.

In a ninth embodiment, the present disclosure provides a method according to any one of the first to eighth embodiments, wherein when at least a portion of the protruding portion is directed in the second direction, it is directed towards the thermoplastic substrate.

In a tenth embodiment, the present disclosure provides a method according to any one of the first to ninth embodiments, wherein multiple tools are carried out simultaneously between multiple rows.

In an eleventh embodiment, the present disclosure provides a method according to a tenth embodiment, at least

EP2582261 some of the many tools have different lengths or are arranged so that their tips are not aligned.

In the twelfth embodiment, the present disclosure provides a method according to the tenth or eleventh embodiment, wherein many tools are automatically positioned between multiple rows of convex elements. In the thirteenth embodiment, the present disclosure provides a method according to any one of the tenth to twelfth embodiments, wherein a plurality of tools are disposed in an instrument comprising a pattern surface with a differentiated structure, wherein the pattern surface with a differentiated structure comprises a reference thermoplastic substrate with multiple rows of pattern convex elements, wherein the reference convex elements comprise protrusions with proximal ends attached to the reference thermoplastic substrate and distal ends, and wherein many tools are sandwiched between multiple rows of reference convex elements on a reference surface of varying structure.

In the fourteenth embodiment, the present disclosure provides the method of the thirteenth embodiment, wherein many rows of master convex elements have the same spatial configuration as many rows of convex members on a thermoplastic substrate.

In the fifteenth embodiment, the present disclosure provides a method according to any one of the first to fourteenth embodiments, wherein the thermoplastic substrate has an x ​​direction and a y direction perpendicular to the x direction, the distal caps having protruding portions extending beyond the tab in both the x direction and the y direction , and wherein the protruding parts extending only in one x direction or y direction are directed in the other direction.

In the sixteenth embodiment, the present disclosure provides the method of the fifteenth embodiment, wherein the further caps are round before the tool passes between two adjacent rows.

seventeenth embodiment, the present disclosure provides the method of the fifteenth embodiment, the distal caps being oval before the tool passes between two adjacent rows.

EP2582261

In an eighteenth embodiment, the present disclosure provides a method according to a fifteenth or sixteenth embodiment, the protruding parts protruding beyond the tab on all sides and are substantially equal in volume.

In a nineteenth embodiment, the present disclosure provides a method according to any one of the first to eighteenth embodiments, the surface of the differentiated structure being a mechanical fastener.

In the twentieth embodiment, the present disclosure provides a method according to any one of the first to nineteenth embodiments, wherein the tool is set at an angle of 15 degrees to 45 degrees relative to the thermoplastic substrate.

In the twenty-first embodiment, the present disclosure provides a method according to any one of the first to twentieth embodiments, wherein the thermoplastic substrate is a web of indefinite length having a machine direction and a transverse direction.

In the twenty-second embodiment, the present disclosure provides the method of the twenty-first embodiment, the projecting parts extending in the lateral direction being directed in the second direction.

In the twenty-third embodiment, the present disclosure provides a method according to any one of the first to twenty-second embodiments, wherein the thermoplastic substrate has a second surface opposite the convex elements, the method further comprising connecting the second surface of the substrate to the carrier.

In the twenty-fourth embodiment, the present disclosure provides a surface with a diverse structure comprising:

thermoplastic substrate having an x ​​direction and a y direction; and convex elements comprising protrusions with proximal ends attached to the thermoplastic substrate and distal caps, each distal cap having protruding parts that protrude beyond the protrusion on all sides, the protruding parts protruding beyond the protrusion on all sides are substantially equal in volume and with at least some of the convex elements

EP2582261, the protruding parts extending in only one x direction or y direction are directed downwards towards the thermoplastic substrate.

In the twenty-fifth embodiment, the present disclosure provides a surface with a differentiated structure according to the twenty-fourth embodiment, wherein for at least some of the convex elements, all of the projecting parts are rounded.

In the twenty-sixth embodiment, the present disclosure provides a surface with a differentiated structure according to the twenty-fifth or twenty-fourth embodiment, the convex elements being arranged in rows on a thermoplastic substrate.

In the twenty-seventh embodiment, the present disclosure provides a surface with a varied structure according to any one of the twenty-fourth to twenty-sixth embodiments, wherein the thermoplastic substrate is a web of indeterminate length having a machine direction and a transverse direction, wherein the y direction is a machine direction, wherein the x direction is a transverse direction and wherein only the protruding parts extending in the transverse direction are directed down towards the thermoplastic substrate.

In the twenty-eighth embodiment, the present disclosure provides a fixing laminate comprising a support member and a structured surface according to any one of the twenty-fourth to the twenty-seventh embodiment, wherein the thermoplastic substrate has a second surface opposite the convex elements and wherein the second surface of the substrate is connected to the support element .

In the twenty-ninth embodiment, the present disclosure provides an absorbent article having at least a front waist area, a back waist area, and a longitudinal axis dividing in half the front waist area and the rear waist area, wherein at least one of the front waist area or rear waist area comprises a securing laminate according to an embodiment

28.

In the thirtieth embodiment, the present disclosure provides a device for forming further attachments on convex elements on a surface with a varied structure, the device comprising a reference surface with a varied structure and a plurality of tools,

EP2582261 a reference surface with a varied structure includes a reference thermoplastic substrate with a plurality of rows of reference convex elements, the reference relief elements comprising protrusions with proximal ends attached to the reference thermoplastic substrate and distal tips, and many tools include at least one of the needles, wires or shims, and is sandwiched between multiple rows of master convex elements on a master surface of varying structure.

In the thirty-first embodiment, the present disclosure provides an apparatus according to embodiment 30, wherein the plurality of tools comprise at least one of needles, wires or shims.

In order for this disclosure to be fully understood, the following examples are provided. It should be understood that these examples are for illustrative purposes only and should not be construed as limiting the scope of this disclosure in any way.

Examples

Hook straps

The hook strips of Comparative Examples 1-4A (available under product number listed in Table 1, on offer from 3M Company based in St. Paul, Minnesota) were manufactured using the method described in US Patent No. 5,845,375 (Miller et al. .). The polymer used to make the hook strips was the ethylene-propylene copolymer available from Dow Chemical Co. based in Midland, Minnesota, under the trade designation "C700-35N". The density of the hooks was 248 hooks per cm² (1,600 hooks per square inch), arranged in a square configuration, and the shape of the bar was conical. Table 1 records the total thickness, base film thickness, basis weight, cap diameter in the CD direction, and cap diameter in the MD direction for comparative examples 1-4A. The cap shapes in comparative examples 1 and 2 were oval. The cap shapes in comparative examples 3, 4 and 4A were round. Comparative Example 4A was prepared based on Comparative Example 4, using the procedure described in US Patent No. 6,132,660 to form "hook heads with downwardly projecting hooking portions".

EP2582261

Table 1

<td>Example</td><td>Base film thickness ^ m)</td><td>Socket Diameter towards CD (pm)</td><td>Attachment Diameter towards MD (pm)</td><td>Whole thickness (Pm)</td><td>gram -round (Gsm)</td>

<td>Comparative Example 1</td><td> 85</td><td> 420</td><td> 300</td><td> 430</td><td> 104</td>

<td>Comparative Example 2</td><td> 85</td><td> 350</td><td> 250</td><td> 470</td><td> 104</td>

<td>Comparative Example 3</td><td> 100</td><td> 350</td><td> 350</td><td> 440</td><td> 117</td>

<td>Comparative Example 4</td><td> 180</td><td> 350</td><td> 350</td><td> 515</td><td> 191</td>

<td>Example comparative 4A</td><td> 180</td><td> 350</td><td> 350</td><td> 510</td><td> 191</td>

The hook strips of examples 1-4 were prepared based on the respective comparative examples (table 2) using the device described in FIG. 7. The tool part 125 of the device consisted of a 2.54 cm (1 inch) strip with 44 hypodermic syringes (size 25) that were spaced apart to align with the rows (MD direction) of the hook strips. Alignment was achieved by using a web with tabs without caps with a density of 248 pins / cm² (1600 ppi (mandrels per square inch))) as a standard for the needle spacing. The needles were placed in rows of webs with insets without caps, and the lower (flat) face of the web with insets was attached to a piece of rubber measuring 6.35 cm (2.5 inches) by 1.27 cm (0.5 inches) at 0, 16 cm (0.0625 inch) double-sided tape. A second piece of rubber 105 of the same dimensions was placed on top of the needles and the resulting tool assembly was placed in the clamp 100 to provide the device of FIG. 7. The needles protrude 1.9 cm (about 0.75 inches) from the edge of the clamp. The needles were placed in line with the rows of the hook strip and the device was pulled manually across the hook strip so that the angle formed between the tool part of the device and the hook strip substrate (in the direction of hand movement) was about 15-45 degrees. Obtained as a result of this

EP2582261 shape change (e.g. between FIG. 8A and FIG 8b) was independent of the angle used.

Table 2

<td>Example number</td><td>Exit hook belt</td>

<td>Example 1</td><td>Comparative Example 1</td>

<td>Example 2</td><td>Comparative Example 2</td>

<td>Example 3</td><td>Comparative Example 3</td>

<td>Example 4</td><td>Comparative Example 4</td>

Test method and test results

The properties associated with the breaking strength of the materials produced in the examples were measured using four different test methods. All tests were carried out at a constant temperature (23 ° C +/- 2 ° C) and constant humidity (50% +/- 5%). All materials and devices were calibrated under these conditions for at least 24 hours prior to testing. A universal tensile tester with a constant tensile speed equipped with a computer for recording data and required load ranges (4200, 4500 or 5500 series available from the Instron Engineering Corporation based in Canton, Minnesota) was used. The instrument head speed was set to 30.5 cm (12 inches) / minute for all tests.

Samples of extrusion bonded loops (EBL) and non-woven loops were obtained by removing loop fastener inserts from commercially available baby diapers. Samples EBL [described in US Patent No. 5,256,231 (Gorman et al.)] Were obtained from New Baby diapers

Size 1 available under the trade designation "PAMPERS SWADDLERS" on offer from Procter &amp; Gamble Company based in Cincinnati, Ohio. Samples of nonwoven loops were obtained from baby diapers in size 4 (available from the Procter &amp; Gamble Company) under the trade designation "LUVS". Samples of nylon knitted loops had a fabric weight of about 22 grams per square meter (gsm) and were covered with biaxially oriented polypropylene (BOPP, about 11 gsm) film.

Test method 1 measured the force needed to detach the hook material from the loop material at a peel angle of 180 degrees with shear engagement. Samples of the finished hooks were prepared

EP2582261 in the form of a 1.27 cm (0.5 inch) transverse (CD) by 2.54 cm (1 inch) in machine (MD) direction, with a fastening tape used as liner. The hook sample was attached almost in the middle of the extended piece of paper (2.54 cm (1 inch)) on (20.32 cm (8 inches)).

The protruding piece was folded in half out of the hook in such a way as to apply a shear engagement on one side and a 180 degree peel on the other. A finished loop element at least 7.62 cm (3 inches) in the CD direction was cut out at 5.08 cm (2 inches) in the MD direction. The hook sample was placed gently with the hook down on the appropriate face of the loop and secured in one cycle (one cycle = one forward and one reverse) of a 2.0 kg (4.5 pound) hand roller. Shear attachment was carried out by suspending a 500 g weight on the finished assembly for 10 seconds. The end of the extended piece, torn off at an angle of 180 degrees, was attached to the lower jaw, while the loop was attached vertically to the extended piece, to the upper jaw of the Instron instrument, leaving a small amount of slack. The materials were positioned so that peeling was carried out in the direction of the hook CD and in the direction of the loop of the loop. The initial jaw spacing (measuring length) was set to 7.62 cm (3 inches). The instrument was started and the upper jaw moved until the hook sample was completely detached from the loop sample. Measurements were made at maximum load (max load), average load (average load) and average peak load (peak average) in gram-force units (gf). Data collected from ten samples, each of which used fresh materials, were averaged and averaged data are presented in Tables 3-5 with their corresponding standard deviation values.

Table 3. CD peeling with EBL as the loop medium

<td>Example</td><td>Max. load (N) ((gf))</td><td>Max. load (StDev)</td><td>Dia. load (N) ((gf))</td><td>Dia. load (StDev)</td><td>Dia. peak (N) ((gf))</td><td>Dia. peak (StDev)</td>

<td>Comparative Example 1</td><td> 11,99 (1223)</td><td> 145</td><td> 4,6 (470)</td><td> 41</td><td> 5,8 (590)</td><td> 112</td>

<td>Example 1</td><td> 10,82 (1103)</td><td> 218</td><td> 4,44 (453)</td><td> 58</td><td> 5,06 (516)</td><td> 104</td>

<td>Example</td><td> 7,20 (734)</td><td> 144</td><td> 1,87 (191)</td><td> 47</td><td> 2,02 (206)</td><td> 61</td>

EP2582261

<td>comparative 2</td><td></td><td></td><td></td><td></td><td></td><td></td>

<td>Example 2</td><td> 8,85 (902)</td><td> 204</td><td> 3,18 (324)</td><td> 92</td><td> 4,26 (434)</td><td> 152</td>

<td>Comparative Example 3</td><td> 4,54 (463)</td><td> 249</td><td> 1,22 (124)</td><td> 62</td><td> 1,44 (147)</td><td> 93</td>

<td>Example 3</td><td> 12,24 (1248)</td><td> 174</td><td> 4,40 (449)</td><td> 76</td><td> 5,47 (558)</td><td> 160</td>

<td>Comparative Example 4</td><td> 4,29 (437)</td><td> 216</td><td> 0,92 (94)</td><td> 47</td><td> 0,96 (98)</td><td> 76</td>

<td>Example comparative 4A</td><td> 15,55 (1586)</td><td> 144</td><td> 4,16 (424)</td><td> 78</td><td> 4,69 (478)</td><td> 269</td>

<td>Example 4</td><td> 14,60 (1489)</td><td> 349</td><td> 4,10 (418)</td><td> 111</td><td> 7,48 (763)</td><td> 532</td>

Table 4. CD peeling with a knitted loop as the loop backing

<td>Example</td><td>Max. load (N) ((gf))</td><td>Max. load (StDev)</td><td>Dia. load (N) ((gf))</td><td>Dia. load (StDev)</td><td>Dia. peak (N) ((gf))</td><td>Dia. peak (StDev)</td>

<td>Comparative Example 1</td><td> 2,47 (252)</td><td> 73</td><td> 0,86 (88)</td><td> 28</td><td> 1,21 (123)</td><td> 39</td>

<td>Example 1</td><td> 1,95 (199)</td><td> 34</td><td> 0,60 (61)</td><td> 12</td><td> 0,9 (90)</td><td> 19</td>

<td>Comparative Example 2</td><td> 1,10 (112)</td><td> 52</td><td> 0,27 (28)</td><td> 13</td><td> 0,48 (49)</td><td> 29</td>

<td>Example 2</td><td> 1,28 (131)</td><td> 58</td><td> 0,31 (32)</td><td> 13</td><td> 0,54 (55)</td><td> 25</td>

<td>Comparative Example 3</td><td> 1,69 (172)</td><td> 35</td><td> 0,52 (53)</td><td> 14</td><td> 0,77 (79)</td><td> 23</td>

<td>Example 3</td><td> 2,76 (281)</td><td> 178</td><td> 0,67 (68)</td><td> 38</td><td> 1,25 (127)</td><td> 76</td>

<td>Comparative Example 4</td><td> 2,36 (241)</td><td> 80</td><td> 0,74 (75)</td><td> 21</td><td> 1,25 (127)</td><td> 41</td>

<td>Example comparative 4A</td><td> 2,03 (207)</td><td> 61</td><td> 0,70 (71)</td><td> 20</td><td> 1,05 (107)</td><td> 30</td>

<td>Example 4</td><td> 2,98 (304)</td><td> 122</td><td> 0,71 (72)</td><td> 31</td><td> 1,45 (148)</td><td> 66</td>

EP2582261

Table 5. CD peeling with non-woven loop as the loop substrate

<td>Example</td><td>Max. load (N) ((gf))</td><td>Max. load (StDev)</td><td>Dia. load (N) ((gf))</td><td>Dia. load (StDev)</td><td>Dia. peak (N) ((gf))</td><td>Dia. peak (StDev)</td>

<td>Comparative Example 1</td><td> 2,80 (286)</td><td> 75</td><td> 1,3 (130)</td><td> 32</td><td> 1,63 (166)</td><td> 46</td>

<td>Example 1</td><td> 1,27 (129)</td><td> 39</td><td> 0,63 (64)</td><td> 19</td><td> 0,77 (79)</td><td> 24</td>

<td>Comparative Example 2</td><td> 2,64 (269)</td><td> 82</td><td> 0,86 (88)</td><td> 35</td><td> 1,31 (134)</td><td> 56</td>

<td>Example 2</td><td> 1,93 (197)</td><td> 57</td><td> 0,91 (93)</td><td> 19</td><td> 1,16 (118)</td><td> 28</td>

<td>Comparative Example 3</td><td> 2,10 (214)</td><td> 49</td><td> 0,71 (72)</td><td> 19</td><td> 0,1 (100)</td><td> 27</td>

<td>Example 3</td><td> 1,8 (180)</td><td> 37</td><td> 0,76 (77)</td><td> 17</td><td> 1,00 (102)</td><td> 20</td>

<td>Comparative Example 4</td><td> 2,43 (248)</td><td> 105</td><td> 0,71 (72)</td><td> 24</td><td> 1,00 (102)</td><td> 34</td>

<td>Example comparative 4A</td><td> 1,25 (127)</td><td> 50</td><td> 0,5 (50)</td><td> 17</td><td> 0,63 (64)</td><td> 21</td>

<td>Example 4</td><td> 1,35 (138)</td><td> 46</td><td> 0,62 (63)</td><td> 19</td><td> 0,8 (80)</td><td> 25</td>

In test method 2, the attachment tabs for the diaper ear from the "Parents Choice" diaper size 4 (available from Walmart Corporation based in Bentonville, Arkansas) were removed and marked to determine the attachment location (located on the right or left side of the diaper). The existing hook material on each fastener tab was removed from the nonwoven support element of the fastener tab. This was done by cooling the overlaps by exposing them to liquid nitrogen and detaching existing hook elements from the nonwoven support element during cooling. The non-woven support element was heated to room temperature, and then the hook strip selected from comparative examples 1-4A and examples 1-4 (in the size 13 mm by 25.4 mm) was placed on the non-woven support element of the diaper attachment tab with two layers of adhesive tape covered with on both sides (available from the 3M Company offer based in St. Paul, Minnesota, under the designation

EP2582261 to commercial "SCOTCH ADHESIVE TRANFER TAPE NO. 924 "). Existing loop media was also removed by the same procedure using the liquid nitrogen described above. The test loop substrate (selected from the three loop samples described above) was attached to the diaper in the same place as the previously removed loop substrate, using "3M SUPER 77 MULTIPURPOSE SPRAY ADHESIVE" (available from 3M Company based in St. Paul Minnesota). The test loop medium was labeled to determine the right and left side of the diaper. Then, the attachment zone area was cut from the diaper containing a test loop approximately 1.27 cm (0.5 inch) by 1.9 cm (0.75 inch) below the attachment zone.

Diaper ear fastening tabs (comprising hook material selected from comparative examples 1-4 and examples 1-4a) were fitted to the appropriate loop substrate (right or left side of the diaper), and the hook was placed downwards on the loop substrate. Each hook strap was gently wiped once in the machine direction, and then further secured in two cycles (one cycle = one forward and one backward) of a 0.5 kg (one pound) hand roller moving in the machine direction of the hook. The duration of one cycle was about two seconds. The attachment zone was cut out in the center to give two ready-made test samples. Part of the wider spacer tab of the hook fastening tab was placed in the upper jaw of the Instron instrument, while the loop substrate was placed in the lower jaw. The materials were positioned so that peeling was carried out in the direction of the hook CD and the direction of the loop of the loop. The initial jaw gap (measuring length) was set to 2.54-5.1 cm (125 2 inches). The instrument was started and the upper jaw moved until the hook sample was completely detached from the loop sample. Measurements were made at maximum load (max load), average load (average load) and average peak load (peak average) in gram-force units (gf). Data collected from five samples, each of which used fresh materials, were averaged and averaged data are presented in Tables 6-8 with their corresponding standard deviation values.

EP2582261

Table 6. CD peeling with EBL as the loop medium

<td>Example</td><td>Max. load (N) ((gf))</td><td>Max. load (StDev)</td><td>Dia. load (N) ((gf))</td><td>Dia. load (StDev)</td><td>Dia. peak (N) ((gf))</td><td>Dia. peak (StDev)</td>

<td>Comparative Example 1</td><td> 9,16 (934)</td><td> 241</td><td> 6 (600)</td><td> 147</td><td> 6,78 (691)</td><td> 171</td>

<td>Example 1</td><td> 10,68 (1089)</td><td> 124</td><td> 6,91 (705)</td><td> 103</td><td> 7,98 (814)</td><td> 133</td>

<td>Comparative Example 2</td><td> 8,70 (887)</td><td> 187</td><td> 5,02 (512)</td><td> 138</td><td> 6,04 (616)</td><td> 184</td>

<td>Example 2</td><td> 10,77 (1098)</td><td> 169</td><td> 6,56 (669)</td><td> 43</td><td> 7,50 (765)</td><td> 80</td>

<td>Comparative Example 3</td><td> 11,04 (1126)</td><td> 225</td><td> 5,06 (516)</td><td> 103</td><td> 5,99 (611)</td><td> 122</td>

<td>Example 3</td><td> 10,58 (1079)</td><td> 153</td><td> 6,48 (661)</td><td> 104</td><td> 7,61 (776)</td><td> 91</td>

<td>Comparative Example 4</td><td> 8,75 (892)</td><td> 352</td><td> 2,88 (294)</td><td> 104</td><td> 3,47 (354)</td><td> 80</td>

<td>Example comparative 4A</td><td> 12,89 (1314)</td><td> 487</td><td> 5,92 (604)</td><td> 222</td><td> 6,60 (673)</td><td> 169</td>

<td>Example 4</td><td> 15,29 (1559)</td><td> 475</td><td> 6,58 (671)</td><td> 109</td><td> 6,72 (685)</td><td> 91</td>

Table 7. CD peeling with a knitted loop as the loop substrate

<td>Example</td><td>Max. load (N) ((gf))</td><td>Max. load (StDev)</td><td>Dia. load (N) ((gf))</td><td>Dia. load (StDev)</td><td>Dia. peak (N) ((gf))</td><td>Dia. peak (StDev)</td>

<td>Comparative Example 1</td><td> 2,14 (218)</td><td> 89</td><td> 0,77 (79)</td><td> 39</td><td> 0,96 (98)</td><td> 57</td>

<td>Example 1</td><td> 2,32 (237)</td><td> 96</td><td> 0,94 (96)</td><td> 41</td><td> 1,19 (121)</td><td> 59</td>

<td>Comparative Example 2</td><td> 1,52 (155)</td><td> 79</td><td> 0,61 (62)</td><td> 32</td><td> 0,67 (68)</td><td> 40</td>

<td>Example 2</td><td> 1,79 (183)</td><td> 50</td><td> 0,82 (84)</td><td> 21</td><td> 0,97 (99)</td><td> 27</td>

<td>Comparative Example 3</td><td> 2,50 (255)</td><td> 49</td><td> 0,93 (95)</td><td> 19</td><td> 1,12 (114)</td><td> .33</td>

<td>Example 3</td><td> 1,87 (191)</td><td> 44</td><td> 0,43 (44)</td><td> 23</td><td> 0,44 (45)</td><td> 25</td>

<td>Comparative Example 4</td><td> 2,2 (220)</td><td> 118</td><td> 0,60 (61)</td><td> 23</td><td> 0,68 (69)</td><td> 29</td>

EP2582261

<td>Example comparative 4A</td><td> 2,7 (270)</td><td> 77</td><td> 0,94 (96)</td><td> 26</td><td> 1,24 (126)</td><td> 34</td>

<td>Example 4</td><td> 2,68 (273)</td><td> 102</td><td> 0,70 (71)</td><td> 21</td><td> 0,7 (70)</td><td> 30</td>

Table 8. CD peeling with nonwoven loop as the loop substrate

<td>Example</td><td>Max. load (N) ((gf))</td><td>Max. load (StDev)</td><td>Dia. load (N) ((gf))</td><td>Dia. load (StDev)</td><td>Dia. peak (N) ((gf))</td><td>Dia. peak (StDev)</td>

<td>Comparative Example 1</td><td> 2,99 (305)</td><td> 46</td><td> 1,95 (199)</td><td> 39</td><td> 2,19 (223)</td><td> 47</td>

<td>Example 1</td><td> 2,88 (294)</td><td> 28</td><td> 1,65 (168)</td><td> 42</td><td> 1,76 (179)</td><td> 45</td>

<td>Comparative Example 2</td><td> 3,88 (396)</td><td> 66</td><td> 2,33 (238)</td><td> 54</td><td> 2,71 (276)</td><td> 38</td>

<td>Example 2</td><td> 3,79 (386)</td><td> 100</td><td> 1,45 (148)</td><td> 42</td><td> 1,88 (192)</td><td> 68</td>

<td>Comparative Example 3</td><td> 2,95 (301)</td><td> 55</td><td> 1,68 (171)</td><td> 62</td><td> 2 (200)</td><td> 66</td>

<td>Example 3</td><td> 4,04 (412)</td><td> 91</td><td> 2,32 (237)</td><td> 73</td><td> 2,49 (254)</td><td> 85</td>

<td>Comparative Example 4</td><td> 3,23 (329)</td><td> 185</td><td> 0,95 (97)</td><td> 71</td><td> 0,92 (94)</td><td> 69</td>

<td>Example comparative 4A</td><td> 3,4 (350)</td><td> 88</td><td> 1,69 (172)</td><td> 26</td><td> 1,87 (191)</td><td> 37</td>

<td>Example 4</td><td> 4,44 (453)</td><td> 83</td><td> 1,98 (202)</td><td> 49</td><td> 2,03 (207)</td><td> 65</td>

In test method 3, the fastening tabs on the diaper ears from Parents Choice diaper size 4 (available from Walmart Corporation based in Bentonville, Arkansas) were removed and marked to determine the attachment location (located on the right or left side of the diaper). The existing hook material on each fastener tab was removed from the nonwoven support element of the fastener tab. This was done by cooling the overlaps by exposing them to liquid nitrogen and detaching existing hook elements from the nonwoven support element during cooling. The nonwoven support element was heated to room temperature followed by a hook strip selected from

EP2582261 comparative examples 1-4A and examples 1-4 (in the size 13 mm by 25.4 mm) were placed on the non-woven support element of the diaper fastening tab with two layers of adhesive tape covered on both sides (available from the offer of 3M Company based in St. Paul, Minnesota, under the trade designation "SCOTCH ADHESIVE TRANFER TAPE NO. 924"). Existing loop media was also removed by the same procedure using the liquid nitrogen described above. The test loop substrate (selected from the three loop samples described above) was attached to the diaper in the same place as the previously removed loop substrate, using "3M SUPER 77 MULTIPURPOSE SPRAY ADHESIVE" (available from the company

3M Company based in St. Paul, Minnesota). The test loop medium was labeled to determine the right and left side of the diaper. Then the attachment zone area was cut from the diaper containing the test loop approximately 1.3 cm (0.5 inch) by 1.9 cm (0.75 inch) below the attachment zone. The ear tab portion containing the hook material was carefully cut out of the tab tab and then attached almost to the center of the protruding piece of paper (2.54 cm by 7.62 cm, 1 inch by 3 inches). Fastening was done with a clip. The clip was placed near the top edge of the hook strap with the flat side of the clip on the front surface of the hook. The hook strips were fitted to the appropriate loop substrate (right or left side of the diaper), and the hook was placed downwards on the loop substrate. Each hook strap was gently wiped once in the machine direction, and then additionally secured in two cycles (one cycle = one forward and one backward) of a 0.5 kg (one pound) hand roller moving in the machine direction of the hook. The duration of one cycle was about two seconds. The attachment zone was cut out in the center to give two ready-made test samples. A protruding piece of paper was placed in the upper jaw of the Instron instrument, while the loop substrate was placed in the lower jaw. The materials were positioned so that the peeling was carried out in the MD direction of the hook and in the MD direction of the loop. The initial gap between the jaws (measuring length) was set to 2.545.1 cm (1-2 inches). The instrument was started and the upper jaw moved until the hook sample was completely detached from the loop sample. Measurements were made at maximum load (max load), medium load

EP2582261 (average load) and average peak load (peak average) in gram-force units (gf). Data collected from five samples, each of which used fresh materials, were averaged and averaged data are presented in Tables 9-11 together with the corresponding standard deviation values.

Table 9. MD peeling with EBL as the loop substrate

<td>Example</td><td>Max. load (N) ((gf))</td><td>Max. load (StDev)</td><td>Dia. load (N) ((gf))</td><td>Dia. load (StDev)</td><td>Dia. peak (N) ((gf))</td><td>Dia. peak (StDev)</td>

<td>Comparative Example 1</td><td> 3 (306)</td><td> 150</td><td> 1,89 (193)</td><td> 89</td><td> 2,03 (207)</td><td> 92</td>

<td>Example 1</td><td> 3,32 (339)</td><td> 79</td><td> 2,21 (225)</td><td> 59</td><td> 2,40 (245)</td><td> 69</td>

<td>Comparative Example 2</td><td> 0,82 (84)</td><td> 29</td><td> 0,43 (44)</td><td> 12</td><td> 0,46 (47)</td><td> 12</td>

<td>Example 2</td><td> 1,75 (178)</td><td> 44</td><td> 1,07 (109)</td><td> 26</td><td> 1,15 (117)</td><td> 29</td>

<td>Comparative Example 3</td><td> 2,59 (264)</td><td> 115</td><td> 1,26 (128)</td><td> 58</td><td> 1,34 (137)</td><td> 69</td>

<td>Example 3</td><td> 3,72 (379)</td><td> 82</td><td> 2,28 (233)</td><td> 43</td><td> 2,56 (261)</td><td> 54</td>

<td>Comparative Example 4</td><td> 0,83 (85)</td><td> 33</td><td> 0,35 (36)</td><td> 15</td><td> 0,38 (39)</td><td> 18</td>

<td>Example comparative 4A</td><td> 4,34 (443)</td><td> 170</td><td> 2,62 (267)</td><td> 68</td><td> 2,88 (294)</td><td> 79</td>

<td>Example 4</td><td> 3,10 (316)</td><td> 75</td><td> 1,87 (191)</td><td> 36</td><td> 2,02 (206)</td><td> 43</td>

Table 10. Tearing in the MD direction with a knitted loop as the loop backing

<td>Example</td><td>Max. load (N) ((gf))</td><td>Max. load (StDev)</td><td>Dia. load (N) ((gf))</td><td>Dia. load (StDev)</td><td>Dia. peak (N) ((gf))</td><td>Dia. peak (StDev)</td>

<td>Comparative Example 1</td><td> 1,11 (113)</td><td> 43</td><td> 0,38 (39)</td><td> 29</td><td> 0,42 (43)</td><td> 34</td>

<td>Example 1</td><td> 1,64 (167)</td><td> 54</td><td> 0,6 (60)</td><td> 14</td><td> 0,62 (63)</td><td> 19</td>

<td>Example</td><td> 0,82 (84)</td><td> 23</td><td> 0,2 (20)</td><td> 3</td><td> 0,23 (23)</td><td> 3</td>

EP2582261

<td>comparative 2</td><td></td><td></td><td></td><td></td><td></td><td></td>

<td>Example 2</td><td> 0,75 (76)</td><td> 23</td><td> 0,17 (17)</td><td> 4</td><td> 0,17 (17)</td><td> 7</td>

<td>Comparative Example 3</td><td> 0,57 (58)</td><td> 21</td><td> 0,17 (17)</td><td> 10</td><td> 0,2 (20)</td><td> 11</td>

<td>Example 3</td><td> 0,67 (68)</td><td> 22</td><td> 0,22 (22)</td><td> 12</td><td> 0,23 (23)</td><td> 11</td>

<td>Comparative Example 4</td><td> 0,40 (41)</td><td> 10</td><td> 0,14 (14)</td><td> 8</td><td> 0,15 (15)</td><td> 8</td>

<td>Example comparative 4A</td><td> 1,05 (107)</td><td> 71</td><td> 0,34 (35)</td><td> 17</td><td> 0,36 (37)</td><td> 21</td>

<td>Example 4</td><td> 0,61 (62)</td><td> 22</td><td> 0,27 (28)</td><td> 13</td><td> 0,27 (28)</td><td> 15</td>

Table 11. MD peeling with a nonwoven loop as the loop substrate

<td>Example</td><td>Max. load (N) ((gf))</td><td>Max. load (StDev)</td><td>Dia. load (N) ((gf))</td><td>Dia. load (StDev)</td><td>Dia. peak (N) ((gf))</td><td>Dia. peak (StDev)</td>

<td>Comparative Example 1</td><td> 1,90 (194)</td><td> 39</td><td> 1,09 (111)</td><td> 13</td><td> 1,12 (114)</td><td> 14</td>

<td>Example 1</td><td> 1,65 (168)</td><td> 24</td><td> 1,2 (120)</td><td> 20</td><td> 1,23 (125)</td><td> 22</td>

<td>Comparative Example 2</td><td> 0,71 (72)</td><td> 14</td><td> 0,32 (33)</td><td> 5</td><td> 0,36 (37)</td><td> 5</td>

<td>Example 2</td><td> 1,22 (124)</td><td> 37</td><td> 0,71 (72)</td><td> 32</td><td> 0,73 (74)</td><td> 34</td>

<td>Comparative Example 3</td><td> 0,80 (82)</td><td> 22</td><td> 0,46 (47)</td><td> 19</td><td> 0,5 (50)</td><td> 19</td>

<td>Example 3</td><td> 1,98 (202)</td><td> 46</td><td> 1,29 (132)</td><td> 35</td><td> 1,4 (140)</td><td> 39</td>

<td>Comparative Example 4</td><td> 0,55 (56)</td><td> 18</td><td> 0,21 (21)</td><td> 11</td><td> 0,21 (21)</td><td> 11</td>

<td>Example comparative 4A</td><td> 1,98 (202)</td><td> 14</td><td> 1,21 (123)</td><td> 23</td><td> 1,27 (129)</td><td> 28</td>

<td>Example 4</td><td> 1,65 (168)</td><td> 39</td><td> 0,97 (99)</td><td> 24</td><td> 1,01 (103)</td><td> 27</td>

Test method 4 measured the force needed to disengage the mechanical fastening system after using the minimum force to attach the hook and loop samples. A 90 degree test apparatus capable of holding a 5.1 cm (2 inch) by 12.7 cm (5 inch) steel plate placed in the lower jaw

EP2582261 Instron tensile testing machines. The bottom (flat) face of a 6.5 cm square piece (1 square inch) of the finished hook sample (selected from comparative examples 1-4A and examples 1-4) was attached with double-sided adhesive tape (available from 3M Company based in St.

Paul, Minnesota, under the trade designation "SCOTCH Double Coated TAPE NO. 9579 ") to the bottom of the 240 g test device. A sample of the finished loop was attached with double-sided tape to completely cover one side of the 5.1 cm (2 inch) by 12.7 cm (5 inch) steel plate CD direction of the loop material aligned parallel to the longer dimension of the disc. The plate containing the hook sample was inserted into the tear-off device at an angle of 90 degrees. The test instrument containing the hook sample was placed in the upper jaw of the Instron instrument and gently placed on the front face of the loop, being careful not to apply pressure. The initial gap between jaws (measuring length) was set to 24 cm (9.5 inches). The instrument was started and the upper jaw moved until the hook sample was completely detached from the loop sample. The measurement of the maximum load (max load) was recorded in gram-force units (gf). Data collected from ten samples, each of which used fresh materials, were averaged and averaged data are presented in Tables 12-14 together with the corresponding standard deviation values.

Table 12. 90 ° disconnection with EBL as the loop substrate

<td>Example</td><td>Max. load (N) ((gf))</td><td>Max. load (StDev)</td>

<td>Comparative Example 1</td><td> 3,09 (315)</td><td> 81</td>

<td>Example 1</td><td> 5,47 (558)</td><td> 160</td>

<td>Comparative Example 2</td><td> 2,3 (230)</td><td> 96</td>

<td>Example 2</td><td> 5,61 (572)</td><td> 254</td>

<td>Comparative Example 3</td><td> 2,46 (251)</td><td> 140</td>

<td>Example 3</td><td> 4,18 (426)</td><td> 181</td>

<td>Comparative Example 4</td><td> 1,52 (155)</td><td> 36</td>

<td>Comparative example 4A</td><td> 3,87 (395)</td><td> 201</td>

EP2582261

<td>Example 4</td><td> 3,91 (399)</td><td> 218</td>

Table 13. Disconnection at an angle of 90 ° with a knitted loop as the loop substrate

<td>Example</td><td>Max. load (N) ((gf))</td><td>Max. load (StDev)</td>

<td>Comparative Example 1</td><td> 1,46 (149)</td><td> 22</td>

<td>Example 1</td><td> 1,66 (169)</td><td> 24</td>

<td>Comparative Example 2</td><td> 1,61 (164)</td><td> 17</td>

<td>Example 2</td><td> 1,49 (152)</td><td> 24</td>

<td>Comparative Example 3</td><td> 1,85 (189)</td><td> 29</td>

<td>Example 3</td><td> 1,99 (203)</td><td> 19</td>

<td>Comparative Example 4</td><td> 1,70 (173)</td><td> 43</td>

<td>Comparative example 4A</td><td> 2,23 (227)</td><td> 35</td>

<td>Example 4</td><td> 2,29 (234)</td><td> 59</td>

Table 14. Disconnection at an angle of 90 ° with a non-woven loop as a loop substrate

<td>Example</td><td>Max. load (N) ((gf))</td><td>Max. load (StDev)</td>

<td>Comparative Example 1</td><td> 1,95 (199)</td><td> 57</td>

<td>Example 1</td><td> 2,83 (289)</td><td> 67</td>

<td>Comparative Example 2</td><td> 2 (200)</td><td> 51</td>

<td>Example 2</td><td> 2,03 (207)</td><td> 60</td>

<td>Comparative Example 3</td><td> 1,84 (188)</td><td> 54</td>

<td>Example 3</td><td> 2,37 (242)</td><td> 80</td>

<td>Comparative Example 4</td><td> 1,72 (175)</td><td> 28</td>

<td>Comparative example 4A</td><td> 2,98 (303)</td><td> 65</td>

<td>Example 4</td><td> 1,95 (199)</td><td> 28</td>

EP2582261

This disclosure may accept various modifications and changes without departing from its scope. Accordingly, the present disclosure is not limited to the embodiments described above, but must be controlled by the limitations set out in the following claims. The present disclosure can advantageously be carried out in the absence of any element not explicitly disclosed herein.

EP2582261