CA2133650A1 - Interengaging fastener member and method of making same - Google Patents
Interengaging fastener member and method of making sameInfo
- Publication number
- CA2133650A1 CA2133650A1 CA002133650A CA2133650A CA2133650A1 CA 2133650 A1 CA2133650 A1 CA 2133650A1 CA 002133650 A CA002133650 A CA 002133650A CA 2133650 A CA2133650 A CA 2133650A CA 2133650 A1 CA2133650 A1 CA 2133650A1
- Authority
- CA
- Canada
- Prior art keywords
- mold
- base
- fastener member
- sacrificial
- head
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/44—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles
- B29C33/52—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles soluble or fusible
-
- A—HUMAN NECESSITIES
- A44—HABERDASHERY; JEWELLERY
- A44B—BUTTONS, PINS, BUCKLES, SLIDE FASTENERS, OR THE LIKE
- A44B18/00—Fasteners of the touch-and-close type; Making such fasteners
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/40—Removing or ejecting moulded articles
- B29C45/44—Removing or ejecting moulded articles for undercut articles
- B29C45/4457—Removing or ejecting moulded articles for undercut articles using fusible, soluble or destructible cores
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S425/00—Plastic article or earthenware shaping or treating: apparatus
- Y10S425/012—Destructible mold and core
Abstract
The present invention relates to a method of forming a fastener member having a base (114) and a plurality of headed stems (118) arranged in columns and rows and projecting from the base. The fastener member is formed by injection molding a molten material into a permanent base mold (102), sacrificial stem mold (100) and permanent head mold (104), wherein the material is solidified.
After the base mold and head mold are removed, the stem mold may be removed to release the fastener member.
After the base mold and head mold are removed, the stem mold may be removed to release the fastener member.
Description
~ 2133650 - I WO~3/~2120 ~ PCI/US93/02942 INTER~:NGAGING FA8~1!ENER NE~BER_AND MEq!~{OD OF MA~ING 8AME
TECHNICAL FIELD
This invention relates to fasteners and specifically to fasteners of the type having two opposed fastener members each including a surface having a plurality of arranged headed stems projecting therefrom.
BACKGROUND_OF_THE INVENTION
Mating fasteners that include two opposed fastener members are popular in a variety of applications.
The particular type of mating fastener with which the present invention is concerned includes two opposed fastener members, each including a surface ha~ing a plurality of arranged headed stems projecting therefrom.
Such fasteners are particularly useful in an environment where it is desirable to interengage the fastener using a relatively small amount of force, while requiring a larger force to separate the fastener members.
A conventional molded polymeric fastener is shown in Figure 1. Included are opposed fastener members 10 and 12, including bases 14 and 16, respectively. Each base includes a plurality of arranged stems 18 or~hogonally projecting therefrom, and each terminating in a head 20 at the respective distal ends of stems 18. The heads have generally arcuate surfaces 22 opposite the ~;
respective bases 14 and 16, which surfa~es are adapted for sliding contact with the encountered ar~uate surfaces 22 of heads 20 when the fastener members are first brought 30 together. Heads 20 also each include a generally planar -~
latching surface 24 extending radially outwardly of the stem, which is adapted to engage a latching surface of an opposed head, as shown in Figure 2.
~igure 1 shows fastener members 10 and 12 ;
35 prepared for engagement, with the heads of one fastener member positioned generally between the heads of the other fastener member. To engage the fastener, fastene`r members i 10 and 12 are urged toward each other with the respective ,~
TECHNICAL FIELD
This invention relates to fasteners and specifically to fasteners of the type having two opposed fastener members each including a surface having a plurality of arranged headed stems projecting therefrom.
BACKGROUND_OF_THE INVENTION
Mating fasteners that include two opposed fastener members are popular in a variety of applications.
The particular type of mating fastener with which the present invention is concerned includes two opposed fastener members, each including a surface ha~ing a plurality of arranged headed stems projecting therefrom.
Such fasteners are particularly useful in an environment where it is desirable to interengage the fastener using a relatively small amount of force, while requiring a larger force to separate the fastener members.
A conventional molded polymeric fastener is shown in Figure 1. Included are opposed fastener members 10 and 12, including bases 14 and 16, respectively. Each base includes a plurality of arranged stems 18 or~hogonally projecting therefrom, and each terminating in a head 20 at the respective distal ends of stems 18. The heads have generally arcuate surfaces 22 opposite the ~;
respective bases 14 and 16, which surfa~es are adapted for sliding contact with the encountered ar~uate surfaces 22 of heads 20 when the fastener members are first brought 30 together. Heads 20 also each include a generally planar -~
latching surface 24 extending radially outwardly of the stem, which is adapted to engage a latching surface of an opposed head, as shown in Figure 2.
~igure 1 shows fastener members 10 and 12 ;
35 prepared for engagement, with the heads of one fastener member positioned generally between the heads of the other fastener member. To engage the fastener, fastene`r members i 10 and 12 are urged toward each other with the respective ,~
2 1 3 3 6 ~ O -2- PCT/US93/02~ ~
bases generally parallel, causing heads 20 to contact and to deflect the attached stems laterally. The lateral `
deflection of the stems allows the heads of one fastener member to pass the heads of ~the opposed fastener member to engage the fastener member~@ in the manner illustrated in Figure 2.
In the past, fasteners of the type discussed above were generally formed by passing a backing layer having a multiplicity of projecting stems beneath a heat source, which heat source tends to melt the stems to form heads atop each of the stems. Such a process is known in the art, as illustrated by U.S. Patent No. 4,29G,832 (Kalleberg), entitled "Nethod for Making Fasteners." The '832 patent discloses a multi-step process for producing a fastener member having a backing layer, a plurality of monofilament stems projecting normally from the backing layer, and a head atop each stem.
The process, illustrated schematically in Figure 3, includes moving two backing layers 50 and 52 in parallel paths while feeding monofilament 54 between the layers, and pressing the monofilaments using applicators 56 and 58, 80 that the monofilaments extend normally between the layers. The monofilaments are severed halfway between the backing layers by blade 60, which produces dual, opposed backing layers each having a plurality of monofilaments extending from each backing. The newly severed terminal ends of the monofilaments are then heated by heat sources 62 and 64 to a temperature sufficient to form a head atop each of the stems. After the heads have solidified, the two fastener members 66 and 68 are wound onto separata rollers 70 and 72, respectively, for dispensation and use.
While having their own utility, the fasteners formed by the process described above tend to exhibit inconsistently shaped heads, which can potentially affect release performance. For example, a generally spherical head having an arcuate latching surface may be unintentionally formed by such a process. An arcuate WO93~22120 _3_ PCT/VS93/02942 latching surface tends to disengage more easily than a planar latching surface extending radially from the stem, and could lower the force required to disengage the fastener. Alternatively, the heads could be irre~ularly formed du~ to the inconsistent application of heat, differences in production speed, and the lik~. Such irregularities could prompt inconsistent release characteristics, which may be undesirable under some circumstances.
10Furthermore, for certain applications it may be : preferable to provide heads that are generally conical, spherical, or some other such desired shape in order to obtain certain engagement and release characteristics. For example, U~s. Patent No. 4,454,183 (Wollman) discloses a three lobed head structure formed by the application of heat to a triangular monofilament stem. However, as discussed above, heads formed by the application of heat to a monofilament stem tend not to be consistently formed.
Furthermore, the number of different head structures is generally limited by the size and shape of the stems from which they are formed.
Another approach to forming heads atop stems in -~
a desired shape is disclosed in Japanese patent publication no. l-238805 (Anzai). The method disclosed in the '805 publication involves forming individual rows of stems by injection molding. Each individual row of stems, which stems may include spherical, conical, or other shaped heads, is typically formed in a mold that is split along the longitudinal axis of the stem. After the molten ;-material has been injected and solidified, the halves of the mold may be separated, and the individual row of stems removed.
In order to form a fastener from the individual rows of stems, several such rows must be aligned and connected together. The individual rows may be connected by means of adhesive, thermal bonding, high frequency bonding, and the like. Although this method of forming a fastener may represent an improvemant over the prior art .~, ... , ., . . .. . .. .. .. . . ~ . , .
2 1 3 3 6 5 0 Pcr/uss3/02 ' `~
in terms of head formation, it involves a greater investment of time and equipment to connect the individual rows together to form the fastener, and is therefore more expensive and undesirable.
Finally, it is often desirable to form a secondary f astening portion on one surface of the fastener, typically the back surface, in order to enable the fastener to be easily attached to a surface, body, or the like. At present, the secondary fastening portion is 10 typically attached to the back of the fastener member by ~:
welding (either solvent, heat, or ultrasonic welding), which requires a manufacturing step separate from the ~;
formation of the fastener portion. The second manufacturing step increases the cost of the article, and is therefore undesirable.
It is therefore desirable to provide a method of making a unitary fastener member having rows and columns -of stems having consistently identical head structures of a desired shape, to provide a method of making a unitary 20 fastener having head structures of different desired `
shapes, and to provid`e a fastener member having an integral secondary fastening portion that i8 formed concurrently with the fastener member. ~;
SUMMARY OF THE INVENTION
According to the present invention there is provided a method of making a fastener member having a base and a plurality of arranged stems each having a proximal end projecting from the base and a distal end ~
30 having a head. The method includes the steps of (a) `
providing a base mold having a cavity adapted to mold the base of the fastener; ~b) providing a sacrificial stem ;
mold having a plurality of arranged passageways for molding the stems; ~c) providing a head mold having a plurality of arranged cavities for molding the heads; (d) securing the sacrificial stem mold adjacent the base mold with the passageways of the stem mold in fluidic communication with the base mold cavity, and securing the , 213~65V
WO93/22120 ~5~ PCT/USg3/O~g42 head mold adjacent the sacrificial stem mold with the head ~-mold cavities in fluidic communication with the passageways of the sacrificial stem mold; (e) flowing a molten plastic into the molds through the inlet passageway in one of the base mold, the sacrificial stem mold, and the head mold to form the base, stems, and heads of the 1 fastener member; (f) solidifying the plastic within the molds to form the fastener member; (g) separating the head mold and the base mold from the sacrificial stem mold and 10 the solidified fastener member; and (h) removing the ~;
¦ sacrificial mold to release the fastener member from the ~sacrificial mold without damage to the fastener member. In ;
one embodiment, the method des¢ribed above includes the step of removing the sacrificial mold by dissolving the ;
mold with a solvent, such as hot water. The invention also "
includes the fastener made by the described method.
Also provided is a mold for making a unitary plastic fastener member comprising a base and a plurality `-of stem~ arranged in columns and rows, each stem having a proximal end projecting from the base and a distal end having a head. The mold includes (a) a base mold having a cavity adapted to mold the baæe of the fastener; (b) a sacrificial stem mold adjacent the base mold and having a plurality of passageways arranged in columns and rows and ~;
in fluidic communication with the base moid cavity to mold `
the stems atop and projecting from the base; and (c) a head mold having a plurality of cavities arranged in columns and rows and in fluidic communication with the -sacrificial stem mold passageways, the head mold cavities I - 30 adapted to mold the heads of the fastener member, the head mold having an inlet passageway communicating at least one of the cavities with an outer wall of the head mold and adapted for t~ansfer of a molten plastic material to the at least one cavity to form the fastener member. The base mold and head mold are adapted for separation from the sacrificial stem mold and plastic fastener member to enable release of the fastener member from the sacrificial stem mold without damage thereto. In one embodiment, the :
WO93/22120 2 1 3 ~ fi 5 -6- PCT/US93/02~q~
sacrificial mold is made of a thermoplastic containing a COOH group that is soluble in an aqueous media.
BRIEF DESCRIPTION OF_ THE DRAWINGS
The invention will be more readily underctood with reference to the accompanying drawings, wherein like reference numerals refer to like components throughout the :-~
several views, and wherein~
Figure 1 is a sectionàl view of a representative fastener of the prior art prior to interengagement of the fastener members;
Figure 2 is a sectional view cf a representative fastener of the prior art following interengagement of the fastener members;
Figure 3 is a schematic representation of a process of the prior art for providing heads to a ~:
plurality of monofilament stems projecting from a base ~-layer; -~
Figure 4 i8 a plan view of a sacrificial stem mold according to one embodiment of the present invention;
Figure 5 is a sectional view of a head mold, a :~
stem mold and a base mold prior to injection molding of the fastener ~ember of the present invention;
Figure 6 is a sectional view of a head mold, ~:~
sacrificial stem mold and a base mold following injection molding of the fastener member of the present invention;
Figure 7 is a sectional view of the fastener member of the present invention with the sacrificial stem mold attached to the stems of the fastener following injection molding of the fastener;
Figure 8 is a sectional view of the fastener member of the present invention after the sacrificial stem mold has been removed from the fastener member;
Figure 9 is a sectional view of a head mold according to one embodiment of the present invention.
Figure lO is a plan view of one embodiment of a fastener according to the present invention;
, ~` 21~6~
W093/22l20 _7_ PCT/US93/02~42 Figures 11 and 12 are sectional views of dif f erent embodiments of a mold according to the present invention; and Figures 13 and 14 are s~ctional views through a sacrificial stem mold, stem, and head of fastener members formed according to an embodiment of the present inventlon.
PETAILED DESCRI~TION
A method is disclosed of forming a ~astener ~:
member having a base, a plurality of stems atop the base . and projecting therefrom, and a plurality of heads :~
connected to distal ends of the stems. The method, which will be described in detail below, generally involves forming a sacrificial stem mold, securing the sacrificial ~tem mold between a base mold and a head mold, injecttng molten or liquid material to form the fastener, separating `
the base and head molds from the sacrificial stem mold to expose the fastener, and removing the ~acrificial stem mold to release the fastener. The method of the present invention will be better understood with reference to Figures 4 through 8, which generally illustrate succeeding steps in the method~
` As shown in Figure 4, a sacrificial stem mold i 25 100 is formed including a p~urality of arranged ¦ passageways 106 corresponding to the desired shape and j location of the stems of the finished fastener member. In ¦ the illustrated embodiment, the passageways are shown in ¦ cross section as being circular, but could also have a ¦ 30 different cross-sectional profile (e.a. square or trianqular, as shown generally at 99 in Figure 4 ) .
Similarly, the sacrificial stem mold 100 could include passageways of two or more cross-sectional configurations within that mold (e.~. alternating rows of circular and 35 square cross-sectional passageways, or alternating circular and square cross-sectional passageways within each row).
WO93/22120 X 1 3 3 6 5 0 -8- PCT/US93/0~
The passageways may be regularly arranged in .~, columns and rows, or may be formed in any other desired arrangement. For example, a generally circular connector ~-110' may be formed, including stems (not shown) and head ~
portions l20' arranged in a pattern comprising a plurality ,., of concentric rings, as shown in Figure lO. Xt is preferred that the passageways,of the sacrificial stem mold be arranged such that ad~àcent passageways are slightly separated from ea~ other. As shown in Figures l, 2, and 4 through 8, a slight separation between each pair of rows of stems facilitates interengagement when opposed fastener members are fastened together, as shown in Figure 2, because the respective stems and attached heads are able to deflect into the space separating adjacent pairs ~
of rows when the respectiva heads contact each other. The ~., proper spacing of each respective row of stems depends on , several factors, including but not limited to the material from which the fastener members are made, the size of the stems and heads, the intended use, and the desired disengagement force.
Sacrificial stem mold lO0 is generally planar, which permits the formation of head portions having generally planar latching portions. In other embodiments, shown in Figures 13 and 14, the sacrificial stem mold lO0' 2S and lO0'' may be adapted to form a configured latching surfaces 124' and l24l', respectively, in order to alter the force necessary to disengage interconnected fastener members. Thus planar latching surfaaes and configured latching surfaces provided by suitable modifications of the sacrificial stem mold are within the scope of the present invention.
The sacrificial stem mold is designed to be durable enough to withstand the injection molding process used to form the fastener member, and to be removed after the fastener member has been formed to release the fastener. The fastener may be "removed" from the sacrificial mold by many different methods, including dissolving the mold with a solvent (e.q. water, acetone, .
~, . . . . .
~I 3365 0 W093/22120 _9_ PCT/US93/02942 or alcohol), disintegrating, melting, shattering (e.q. by force or ultrasonic wave transmission), cutting, or `
otherwise removing the sacrifirial stem mold from around the stems without damaging the fastener member.
In the preferred embodiment, the sacrificial stem mold material (hereinafter "stem mold material") is a water soluble material. This allows the sacrificial mold ~-to be removed from the fastener by applying water to the -~-mold and agitating or vibrating the mold (e.a. by ultrasonic or mechanical vibration) to dissolve the mold.
- For example, the materials disclosed in European ~atent `
Application No. 0,314,156 (Delbig), which is hereby incorporated by reference, pertain to thermoplastic mixtures of fillers and polymers containing COOH groups, 15 which are soluble in aqueous or aqueous-alkaline media.
Such mixtures can be thermoplastically formed into solid parts, which can be dissolved after use. An example of - such a material that may be suitable for certain ;
applications is available from the Belland Ag. of Switzerland under the designation GB~-1330. Further examples of materials that may be useful in forming the sacrificial stem mold of the present invention are disclosed in United States Patent Nos. 4,990,146 (Delbig et al.), which discloses an amino-group containing polymer that is soluble in an acid medium, and 4,870,148 (Belz et - al.) which discloses polymers that are soluble in an alkaline medium. Yet another resin that may have applicability to the sacrificial stem mold comprises `
approximately 70% polyvinylalcohol, 30% talc and a trace of glycerine, and is available from Riken Vinyl Industry Co., Ltd., of Tokyo, Japan. Other combinations of sacrificial stem mold material and solvent are considered to be within the scope of the present invention, as is any other sacrificial stem mold material that may be removed as previously described.
The sacrificial stem mold is typically formed by injection molding, which is well known in the art, as shown in 8 Encvclopedia of Polymer Science and Enaineerina ~13'3650 -' WO93/22120 -10- PCT/US93/02~2 102-34 (Wiley 1987), the disclosure of which is hereby incorporated by reference. Injection molding generally -involves providing a die having a cavity, which cavity is ~
connected to the outside of the die by an inlet `
5 passageway. The die is usually split into at least two ~-parts, allowing the die parts to be separated to remove an article formed therein. Molten material is flowed into the die cavity through the inlet passageway, where the "
material solidifies to form-an article that is shaped by the contours of the cavity. When the material has solidified, the die is removed to expose the finished article. Although the process has been described only -`
summarily, in~ection molding is known in the art, and -therefore only portions of the process and equipment will be shown and described herein. Other methods of forming a sacrificial stem mold, such as pouring the stem mold material into an open face mold or forming holes in a stem mold sheet member, are also included within the scope of the present invention.
After the ~acrificial stem mold 100 has been `
formed, it is placed between a base mold 102 and a head mold 104 in preparation for injection molding the fastener member of the present invention, as shown in Figure 5.
Base mold 102 and head mold 104 are both permanent molds, meaning tbat they are not intended to be broken or destroyed to release the fastener. In general, base mold ' 102, sacrificial stem mold 100 and head mold 104 are positioned with the cavities of each mold positioned in fluidic COD unication with the corresponding cavities of the adjacent mold, as shown in Figure 61 in order to form ¦ the fastener member of the present invention.
Base mold 102 includes an inlet passageway 108 I that communicates with ~av~ty 109, as shown in Figure 5.
Inlet passageway 108 may ent~r from any side or the bottom of base mold 102, and is adapted to permit transfer of the molten material from a source of such material into cavity 109. It may be desirable for inlet passageway to be generally fan-shaped, in order to spread the flow of ~133650 molten material more evenly within cavity 109. In the illustrated embodiment, inlet passageway 108 enters cavity 109 from a side of base mold 102, as shown in Figure 5.
Alternatively, inlet passageways 108' may be formed in head mold 104', whereby inlet passageway 108' is ~-fluidically connécted to one or more head cavities 107', `~
as shown in Figure 11. In yet another embodiment, inlet passageway 108'' enters through head mold 104'' and `
sacrificial stem mold 100'' to fluidically communicate with cavity 109'', as shown in Figure 12.
Cavity 109 is shaped to form the base of the fastener member, which may be of various different ~`
dimensions depending on the application. In the illustrated embodiment, cavity 109 is adapted to form a flat base having a width that is greater than its thicknèss, but other embodiments are also possible, such as a base mold 102 that is much larger than the stem and head portions formed thereon. For example, a large panel (e.a. an automotive body panel or trim component) could be formed within base mold 102, with one or more groupings of arranged stem and head portions projecting therefrom. Thus the base mold, although shown as relatively small with respect to the head and stem molds, should be understood to include base molds adapted to form base portions that are much larger and more detailed than those illustrated herein.
Alternatively, base mold 102 may be dimensioned to provide a secondary fastening portion, shown in Figures 5-8 as screw thread 111, adjoining base 114, which enables attachment of fastener member 110 to a body, surface, or the like. Inlet passageway 108 could also be adapted tQ
form such a secondary fastening portion. It is a further `
advantage of the preferred method of injection molding the fastener member of the present invention that the secondary fastening portion may be injection molded simultaneously with the remainder of the fastener member.
The method of the prior art described above typically involves a second manufacturing step to weld a secondary 213365~ ```
W093/22l20 - -12- PCT/USg3/02 fastening portion to the fastener member, either using a solvent, heat or ultrasonic horn, each of which is more complicated and therefore more expensive than the integrated method of the present invention.
Sacrificial stem mold 100 is positioned atop base mold 102 such that molten material will fill cavity ~`
109 to form the base, and flow ~nto passageways 106 to form stems 118 and into head ~avities 107 of head mold 104 ~-to form heads 120, as described below. After molten material is injected to form the fastener, each of stems 118 will have a proximal e~d 117 that is anchored to base 114, and a distal end 119 that projects from base 114, as shown in Figure 8.
As shown in Figure 5, head mold 104 is positioned atop sacrificial stem mold 100, and includes a plurality of arranged head cavities 107 that are adapted to mold heads 120 atop the respective distal ends 119 of the stems. Head cavities 107 are in fluidic communication with the respective passageways 106 that form stems 118, in order that molten material flow through passageways 106 to form heads 120. Head cavities 107 may be formed in one of many different shapes, including head cavities that are conical, hemispherical, cylindrical, cubic, spherical or the like. For example, Figure 9 shows head cavities that are generally conical (107') and generally cubic (107'').
In the embodiment illustrated in Figures 1, 2, and 4-8, head cavities 107 are shown as a mushroom shape.
The following non-limiting example of a fastener member designed and formed according to the present invention is provided to illustrate the relative dimensions of the fastener member, and therefore of the base mold cavity, the sacrificial stem mold passageways, and the head mold cavities. The fastener member includes a base layer measuring approximately .15 cm. (.06") thick, a plurality of cylindrical stems measuring .08 cm. t.03") in diameter and .18 cm. (.07") high, and a plurality of generally conical heads having a base diameter measuring approximately .165 cm. (.065") and a height of ~ 213365U ~
WO~3J22120 -13- PCT/US93/02942 -approximately .13 cm. (.05"). The stems are arranged in -sets of rows, such that the two rows of each pair of rows are separated by approximately .2 cm. t.08") on center, and that each pair of rows is separated from each adjacent 5 pair of rows by approximately .24 cm. (.093") on center.
It should be noted that widely spaced ~tems having small `-7 heads will tend to require smaller engagement and disengagement forces, whereas closely spaced stems having large heads will require larger engagement and 10 disengagement forces.
After base mold 102, sacrificial stem mold lOo and head mold 104 have been properly aligned and secured together in a manner known in the art, a suitable molten plastic material may be injected through inlet passageway 108 to form fastener member 110, as shown in Figure 6. As used herein, "plastic" includes all mon~mers, polymers, and oligomers and mixtures thereof. Injection molding is preferred manner of forming the fastener member of the present invention, because resins with higher melting 20 points may be used to form the fastener member when it is injection molded than when the stems must be heated to form heads atop individual monofilaments according to the prior art. For example, polypropylene may be used to form fastener members by the prior art method of heating the 25 monofilament stems, because it has a relatively low melting point and the ends of the stems are more easily heated to form the heads. Resins such as nylon, however, may be less desirable for the prior art method because nylon has a higher melting temperature, and it may 30 therefore be more difficult to control the formation of a head atop a monofilament by heating. With the method of the present invention, nylon (and other materials that have relatively high melting points) may be used to form the fastener member by injection molding, which may 35 produce a stronger fastener.
Alternatively, a process known as reaction-injection molding (RIM) has also been shown to have utility, and generally involves supplying and mixing the proper reactive liquid components and injecting them into a mold where the mixture is polymerized to form a plastic article. Materials such as polyurethane, polyester and nylon may be reaction-injection molded in accordance with the present invention.
The type of material selected to form the fastener member (hereinafter "fastener material") depends upon the application, and materials such as polypropylene (e.a. product ~ 8826J avai~a~le from Mitsubishi-kasai), -`
polyacetal (e.~. product~'M90-44 available from Polyplastic), nylon (e.q. product ~ 1220S available from Asahi-kasei), ionomer (e.a. product ~ 1554 available from Mitusi DuPont Chemical), and thermocurable plastics such as phenolic resins and polyurethane resins have been shown to have utility. The fastener material should ~ot chemically interact with the stem mold material or otherwise detrimentally affect the structure or -- performance of the sacrificial stem mold. Furthermore, as ~;
noted above, the stem mold material should be resistant to the injection molding process used to form the fastener member.
The following data illustrate several nonlimiting sample parameters of the molding step of the present invention.
I . j , .- . .
Stem Polypro Poly-Ionomer Nylon l Mold pylene acetal 66 I _ .
¦Resin 190 C 190 C 160 C 190 C 260 C
¦Temp.
I _ ._ ¦Max. 1200 1200 1200 1200 1200 ¦Press. kg/cm2 kg/cm2 kg/cm2 kglcm kg/cm2 ¦Molding 30 sec 30 sec 25 sec 30 sec 30 sec I I
co~ ~S -c IS ~-~ lO ~o lS ~-~ lS ~-~
W093/22l20 -i5- PCT~US93/02~42 These samples were run on an Auto Shot C series Model 30A injection molding machine available from Fanuc Co. Ltd. of Tokyo, Japan. The resin was injected into the mold at a flow rate of 10-50 mm/second, and the pressure 5 was limited to a maximum of 1200 kg/cm2. The mold locking -force was approximately 30 tons.
The newly formed fastener is typ~cally allowed to harden while within the base, stem and head molds.
Under some circumstances, the fastener material may cure more quickly or effectively if heat is applied. Base mold 102 and head mold 104 are removed when fastener member 110 has hardened, which leaves sacrificial stem mold 100 attached to the stems of the fastener member, as shown in Figure 7. Sacrificial stem mold 100 is then removed to release fastener member 110 from the stem mold, as illustrated in Figure 8. In the preferred embodiment, the sacrificial stem mold is removed by the application of a solvent, prefera~ly water, to the sacrificial mold material to dissolve the sacrificial mold. In the most preferred embodiment, the sacrificial stem mold is removed by dissolving it with hot water. Mechanical or ultrasonic vibration, preferably in combination with a solvent, but perhaps without the solvent, may expedite the removal of sacrificial stem mold from fastener 110.
To engage opposed fastener members, which may be formed by dividing a single fastener member into two parts, the fastener members are aligned as shown with respect to the prior art in Figure l. Compressive force applied to the respective bases tends to interengage the fastener members, as ~hown in Figure 2 with respect to the prior art. As explained previously, the level of force -~
neceæsary to engage and disengage the fastener members can be controlled by altering the dimensions and spacing of the stems and heads.
- 35 It is believed that, for certain geometries, the force required to di~engage the fastener members constructed acco-ding to the present invention may be much greater (e.~. two times greater) than that required to '~133650 ~
WO93122120 - -16- PCT/US93/02~
separate comparabIe f~steners constructed according to the method of the prior art. Thus the present invention provides greater control over the formation of the shape of the heads, resulting in a fastener that exhibits greater holding power. It is further believed that the force required to engage the fastener member of the present invention may be higher than the force reguired to engage comparable fastener memb~ers formed according to the method of the prior art, altb~ugh it is believed that such engagement forces may be con`trolled by varying the head shape, stem spacing and rèsin modulus.
The present invention has now been described with reference to several embodiments thereof. It will be apparent to those skilled in the art that many changes can -~-15 be made in the embodiments described without departing ~;
from the scope of the invention. Thus, the scope of the present invention should not be limited to the structures described herein, but only by structures described by the language of the claims and the equivalents of those -~
structures.
.
bases generally parallel, causing heads 20 to contact and to deflect the attached stems laterally. The lateral `
deflection of the stems allows the heads of one fastener member to pass the heads of ~the opposed fastener member to engage the fastener member~@ in the manner illustrated in Figure 2.
In the past, fasteners of the type discussed above were generally formed by passing a backing layer having a multiplicity of projecting stems beneath a heat source, which heat source tends to melt the stems to form heads atop each of the stems. Such a process is known in the art, as illustrated by U.S. Patent No. 4,29G,832 (Kalleberg), entitled "Nethod for Making Fasteners." The '832 patent discloses a multi-step process for producing a fastener member having a backing layer, a plurality of monofilament stems projecting normally from the backing layer, and a head atop each stem.
The process, illustrated schematically in Figure 3, includes moving two backing layers 50 and 52 in parallel paths while feeding monofilament 54 between the layers, and pressing the monofilaments using applicators 56 and 58, 80 that the monofilaments extend normally between the layers. The monofilaments are severed halfway between the backing layers by blade 60, which produces dual, opposed backing layers each having a plurality of monofilaments extending from each backing. The newly severed terminal ends of the monofilaments are then heated by heat sources 62 and 64 to a temperature sufficient to form a head atop each of the stems. After the heads have solidified, the two fastener members 66 and 68 are wound onto separata rollers 70 and 72, respectively, for dispensation and use.
While having their own utility, the fasteners formed by the process described above tend to exhibit inconsistently shaped heads, which can potentially affect release performance. For example, a generally spherical head having an arcuate latching surface may be unintentionally formed by such a process. An arcuate WO93~22120 _3_ PCT/VS93/02942 latching surface tends to disengage more easily than a planar latching surface extending radially from the stem, and could lower the force required to disengage the fastener. Alternatively, the heads could be irre~ularly formed du~ to the inconsistent application of heat, differences in production speed, and the lik~. Such irregularities could prompt inconsistent release characteristics, which may be undesirable under some circumstances.
10Furthermore, for certain applications it may be : preferable to provide heads that are generally conical, spherical, or some other such desired shape in order to obtain certain engagement and release characteristics. For example, U~s. Patent No. 4,454,183 (Wollman) discloses a three lobed head structure formed by the application of heat to a triangular monofilament stem. However, as discussed above, heads formed by the application of heat to a monofilament stem tend not to be consistently formed.
Furthermore, the number of different head structures is generally limited by the size and shape of the stems from which they are formed.
Another approach to forming heads atop stems in -~
a desired shape is disclosed in Japanese patent publication no. l-238805 (Anzai). The method disclosed in the '805 publication involves forming individual rows of stems by injection molding. Each individual row of stems, which stems may include spherical, conical, or other shaped heads, is typically formed in a mold that is split along the longitudinal axis of the stem. After the molten ;-material has been injected and solidified, the halves of the mold may be separated, and the individual row of stems removed.
In order to form a fastener from the individual rows of stems, several such rows must be aligned and connected together. The individual rows may be connected by means of adhesive, thermal bonding, high frequency bonding, and the like. Although this method of forming a fastener may represent an improvemant over the prior art .~, ... , ., . . .. . .. .. .. . . ~ . , .
2 1 3 3 6 5 0 Pcr/uss3/02 ' `~
in terms of head formation, it involves a greater investment of time and equipment to connect the individual rows together to form the fastener, and is therefore more expensive and undesirable.
Finally, it is often desirable to form a secondary f astening portion on one surface of the fastener, typically the back surface, in order to enable the fastener to be easily attached to a surface, body, or the like. At present, the secondary fastening portion is 10 typically attached to the back of the fastener member by ~:
welding (either solvent, heat, or ultrasonic welding), which requires a manufacturing step separate from the ~;
formation of the fastener portion. The second manufacturing step increases the cost of the article, and is therefore undesirable.
It is therefore desirable to provide a method of making a unitary fastener member having rows and columns -of stems having consistently identical head structures of a desired shape, to provide a method of making a unitary 20 fastener having head structures of different desired `
shapes, and to provid`e a fastener member having an integral secondary fastening portion that i8 formed concurrently with the fastener member. ~;
SUMMARY OF THE INVENTION
According to the present invention there is provided a method of making a fastener member having a base and a plurality of arranged stems each having a proximal end projecting from the base and a distal end ~
30 having a head. The method includes the steps of (a) `
providing a base mold having a cavity adapted to mold the base of the fastener; ~b) providing a sacrificial stem ;
mold having a plurality of arranged passageways for molding the stems; ~c) providing a head mold having a plurality of arranged cavities for molding the heads; (d) securing the sacrificial stem mold adjacent the base mold with the passageways of the stem mold in fluidic communication with the base mold cavity, and securing the , 213~65V
WO93/22120 ~5~ PCT/USg3/O~g42 head mold adjacent the sacrificial stem mold with the head ~-mold cavities in fluidic communication with the passageways of the sacrificial stem mold; (e) flowing a molten plastic into the molds through the inlet passageway in one of the base mold, the sacrificial stem mold, and the head mold to form the base, stems, and heads of the 1 fastener member; (f) solidifying the plastic within the molds to form the fastener member; (g) separating the head mold and the base mold from the sacrificial stem mold and 10 the solidified fastener member; and (h) removing the ~;
¦ sacrificial mold to release the fastener member from the ~sacrificial mold without damage to the fastener member. In ;
one embodiment, the method des¢ribed above includes the step of removing the sacrificial mold by dissolving the ;
mold with a solvent, such as hot water. The invention also "
includes the fastener made by the described method.
Also provided is a mold for making a unitary plastic fastener member comprising a base and a plurality `-of stem~ arranged in columns and rows, each stem having a proximal end projecting from the base and a distal end having a head. The mold includes (a) a base mold having a cavity adapted to mold the baæe of the fastener; (b) a sacrificial stem mold adjacent the base mold and having a plurality of passageways arranged in columns and rows and ~;
in fluidic communication with the base moid cavity to mold `
the stems atop and projecting from the base; and (c) a head mold having a plurality of cavities arranged in columns and rows and in fluidic communication with the -sacrificial stem mold passageways, the head mold cavities I - 30 adapted to mold the heads of the fastener member, the head mold having an inlet passageway communicating at least one of the cavities with an outer wall of the head mold and adapted for t~ansfer of a molten plastic material to the at least one cavity to form the fastener member. The base mold and head mold are adapted for separation from the sacrificial stem mold and plastic fastener member to enable release of the fastener member from the sacrificial stem mold without damage thereto. In one embodiment, the :
WO93/22120 2 1 3 ~ fi 5 -6- PCT/US93/02~q~
sacrificial mold is made of a thermoplastic containing a COOH group that is soluble in an aqueous media.
BRIEF DESCRIPTION OF_ THE DRAWINGS
The invention will be more readily underctood with reference to the accompanying drawings, wherein like reference numerals refer to like components throughout the :-~
several views, and wherein~
Figure 1 is a sectionàl view of a representative fastener of the prior art prior to interengagement of the fastener members;
Figure 2 is a sectional view cf a representative fastener of the prior art following interengagement of the fastener members;
Figure 3 is a schematic representation of a process of the prior art for providing heads to a ~:
plurality of monofilament stems projecting from a base ~-layer; -~
Figure 4 i8 a plan view of a sacrificial stem mold according to one embodiment of the present invention;
Figure 5 is a sectional view of a head mold, a :~
stem mold and a base mold prior to injection molding of the fastener ~ember of the present invention;
Figure 6 is a sectional view of a head mold, ~:~
sacrificial stem mold and a base mold following injection molding of the fastener member of the present invention;
Figure 7 is a sectional view of the fastener member of the present invention with the sacrificial stem mold attached to the stems of the fastener following injection molding of the fastener;
Figure 8 is a sectional view of the fastener member of the present invention after the sacrificial stem mold has been removed from the fastener member;
Figure 9 is a sectional view of a head mold according to one embodiment of the present invention.
Figure lO is a plan view of one embodiment of a fastener according to the present invention;
, ~` 21~6~
W093/22l20 _7_ PCT/US93/02~42 Figures 11 and 12 are sectional views of dif f erent embodiments of a mold according to the present invention; and Figures 13 and 14 are s~ctional views through a sacrificial stem mold, stem, and head of fastener members formed according to an embodiment of the present inventlon.
PETAILED DESCRI~TION
A method is disclosed of forming a ~astener ~:
member having a base, a plurality of stems atop the base . and projecting therefrom, and a plurality of heads :~
connected to distal ends of the stems. The method, which will be described in detail below, generally involves forming a sacrificial stem mold, securing the sacrificial ~tem mold between a base mold and a head mold, injecttng molten or liquid material to form the fastener, separating `
the base and head molds from the sacrificial stem mold to expose the fastener, and removing the ~acrificial stem mold to release the fastener. The method of the present invention will be better understood with reference to Figures 4 through 8, which generally illustrate succeeding steps in the method~
` As shown in Figure 4, a sacrificial stem mold i 25 100 is formed including a p~urality of arranged ¦ passageways 106 corresponding to the desired shape and j location of the stems of the finished fastener member. In ¦ the illustrated embodiment, the passageways are shown in ¦ cross section as being circular, but could also have a ¦ 30 different cross-sectional profile (e.a. square or trianqular, as shown generally at 99 in Figure 4 ) .
Similarly, the sacrificial stem mold 100 could include passageways of two or more cross-sectional configurations within that mold (e.~. alternating rows of circular and 35 square cross-sectional passageways, or alternating circular and square cross-sectional passageways within each row).
WO93/22120 X 1 3 3 6 5 0 -8- PCT/US93/0~
The passageways may be regularly arranged in .~, columns and rows, or may be formed in any other desired arrangement. For example, a generally circular connector ~-110' may be formed, including stems (not shown) and head ~
portions l20' arranged in a pattern comprising a plurality ,., of concentric rings, as shown in Figure lO. Xt is preferred that the passageways,of the sacrificial stem mold be arranged such that ad~àcent passageways are slightly separated from ea~ other. As shown in Figures l, 2, and 4 through 8, a slight separation between each pair of rows of stems facilitates interengagement when opposed fastener members are fastened together, as shown in Figure 2, because the respective stems and attached heads are able to deflect into the space separating adjacent pairs ~
of rows when the respectiva heads contact each other. The ~., proper spacing of each respective row of stems depends on , several factors, including but not limited to the material from which the fastener members are made, the size of the stems and heads, the intended use, and the desired disengagement force.
Sacrificial stem mold lO0 is generally planar, which permits the formation of head portions having generally planar latching portions. In other embodiments, shown in Figures 13 and 14, the sacrificial stem mold lO0' 2S and lO0'' may be adapted to form a configured latching surfaces 124' and l24l', respectively, in order to alter the force necessary to disengage interconnected fastener members. Thus planar latching surfaaes and configured latching surfaces provided by suitable modifications of the sacrificial stem mold are within the scope of the present invention.
The sacrificial stem mold is designed to be durable enough to withstand the injection molding process used to form the fastener member, and to be removed after the fastener member has been formed to release the fastener. The fastener may be "removed" from the sacrificial mold by many different methods, including dissolving the mold with a solvent (e.q. water, acetone, .
~, . . . . .
~I 3365 0 W093/22120 _9_ PCT/US93/02942 or alcohol), disintegrating, melting, shattering (e.q. by force or ultrasonic wave transmission), cutting, or `
otherwise removing the sacrifirial stem mold from around the stems without damaging the fastener member.
In the preferred embodiment, the sacrificial stem mold material (hereinafter "stem mold material") is a water soluble material. This allows the sacrificial mold ~-to be removed from the fastener by applying water to the -~-mold and agitating or vibrating the mold (e.a. by ultrasonic or mechanical vibration) to dissolve the mold.
- For example, the materials disclosed in European ~atent `
Application No. 0,314,156 (Delbig), which is hereby incorporated by reference, pertain to thermoplastic mixtures of fillers and polymers containing COOH groups, 15 which are soluble in aqueous or aqueous-alkaline media.
Such mixtures can be thermoplastically formed into solid parts, which can be dissolved after use. An example of - such a material that may be suitable for certain ;
applications is available from the Belland Ag. of Switzerland under the designation GB~-1330. Further examples of materials that may be useful in forming the sacrificial stem mold of the present invention are disclosed in United States Patent Nos. 4,990,146 (Delbig et al.), which discloses an amino-group containing polymer that is soluble in an acid medium, and 4,870,148 (Belz et - al.) which discloses polymers that are soluble in an alkaline medium. Yet another resin that may have applicability to the sacrificial stem mold comprises `
approximately 70% polyvinylalcohol, 30% talc and a trace of glycerine, and is available from Riken Vinyl Industry Co., Ltd., of Tokyo, Japan. Other combinations of sacrificial stem mold material and solvent are considered to be within the scope of the present invention, as is any other sacrificial stem mold material that may be removed as previously described.
The sacrificial stem mold is typically formed by injection molding, which is well known in the art, as shown in 8 Encvclopedia of Polymer Science and Enaineerina ~13'3650 -' WO93/22120 -10- PCT/US93/02~2 102-34 (Wiley 1987), the disclosure of which is hereby incorporated by reference. Injection molding generally -involves providing a die having a cavity, which cavity is ~
connected to the outside of the die by an inlet `
5 passageway. The die is usually split into at least two ~-parts, allowing the die parts to be separated to remove an article formed therein. Molten material is flowed into the die cavity through the inlet passageway, where the "
material solidifies to form-an article that is shaped by the contours of the cavity. When the material has solidified, the die is removed to expose the finished article. Although the process has been described only -`
summarily, in~ection molding is known in the art, and -therefore only portions of the process and equipment will be shown and described herein. Other methods of forming a sacrificial stem mold, such as pouring the stem mold material into an open face mold or forming holes in a stem mold sheet member, are also included within the scope of the present invention.
After the ~acrificial stem mold 100 has been `
formed, it is placed between a base mold 102 and a head mold 104 in preparation for injection molding the fastener member of the present invention, as shown in Figure 5.
Base mold 102 and head mold 104 are both permanent molds, meaning tbat they are not intended to be broken or destroyed to release the fastener. In general, base mold ' 102, sacrificial stem mold 100 and head mold 104 are positioned with the cavities of each mold positioned in fluidic COD unication with the corresponding cavities of the adjacent mold, as shown in Figure 61 in order to form ¦ the fastener member of the present invention.
Base mold 102 includes an inlet passageway 108 I that communicates with ~av~ty 109, as shown in Figure 5.
Inlet passageway 108 may ent~r from any side or the bottom of base mold 102, and is adapted to permit transfer of the molten material from a source of such material into cavity 109. It may be desirable for inlet passageway to be generally fan-shaped, in order to spread the flow of ~133650 molten material more evenly within cavity 109. In the illustrated embodiment, inlet passageway 108 enters cavity 109 from a side of base mold 102, as shown in Figure 5.
Alternatively, inlet passageways 108' may be formed in head mold 104', whereby inlet passageway 108' is ~-fluidically connécted to one or more head cavities 107', `~
as shown in Figure 11. In yet another embodiment, inlet passageway 108'' enters through head mold 104'' and `
sacrificial stem mold 100'' to fluidically communicate with cavity 109'', as shown in Figure 12.
Cavity 109 is shaped to form the base of the fastener member, which may be of various different ~`
dimensions depending on the application. In the illustrated embodiment, cavity 109 is adapted to form a flat base having a width that is greater than its thicknèss, but other embodiments are also possible, such as a base mold 102 that is much larger than the stem and head portions formed thereon. For example, a large panel (e.a. an automotive body panel or trim component) could be formed within base mold 102, with one or more groupings of arranged stem and head portions projecting therefrom. Thus the base mold, although shown as relatively small with respect to the head and stem molds, should be understood to include base molds adapted to form base portions that are much larger and more detailed than those illustrated herein.
Alternatively, base mold 102 may be dimensioned to provide a secondary fastening portion, shown in Figures 5-8 as screw thread 111, adjoining base 114, which enables attachment of fastener member 110 to a body, surface, or the like. Inlet passageway 108 could also be adapted tQ
form such a secondary fastening portion. It is a further `
advantage of the preferred method of injection molding the fastener member of the present invention that the secondary fastening portion may be injection molded simultaneously with the remainder of the fastener member.
The method of the prior art described above typically involves a second manufacturing step to weld a secondary 213365~ ```
W093/22l20 - -12- PCT/USg3/02 fastening portion to the fastener member, either using a solvent, heat or ultrasonic horn, each of which is more complicated and therefore more expensive than the integrated method of the present invention.
Sacrificial stem mold 100 is positioned atop base mold 102 such that molten material will fill cavity ~`
109 to form the base, and flow ~nto passageways 106 to form stems 118 and into head ~avities 107 of head mold 104 ~-to form heads 120, as described below. After molten material is injected to form the fastener, each of stems 118 will have a proximal e~d 117 that is anchored to base 114, and a distal end 119 that projects from base 114, as shown in Figure 8.
As shown in Figure 5, head mold 104 is positioned atop sacrificial stem mold 100, and includes a plurality of arranged head cavities 107 that are adapted to mold heads 120 atop the respective distal ends 119 of the stems. Head cavities 107 are in fluidic communication with the respective passageways 106 that form stems 118, in order that molten material flow through passageways 106 to form heads 120. Head cavities 107 may be formed in one of many different shapes, including head cavities that are conical, hemispherical, cylindrical, cubic, spherical or the like. For example, Figure 9 shows head cavities that are generally conical (107') and generally cubic (107'').
In the embodiment illustrated in Figures 1, 2, and 4-8, head cavities 107 are shown as a mushroom shape.
The following non-limiting example of a fastener member designed and formed according to the present invention is provided to illustrate the relative dimensions of the fastener member, and therefore of the base mold cavity, the sacrificial stem mold passageways, and the head mold cavities. The fastener member includes a base layer measuring approximately .15 cm. (.06") thick, a plurality of cylindrical stems measuring .08 cm. t.03") in diameter and .18 cm. (.07") high, and a plurality of generally conical heads having a base diameter measuring approximately .165 cm. (.065") and a height of ~ 213365U ~
WO~3J22120 -13- PCT/US93/02942 -approximately .13 cm. (.05"). The stems are arranged in -sets of rows, such that the two rows of each pair of rows are separated by approximately .2 cm. t.08") on center, and that each pair of rows is separated from each adjacent 5 pair of rows by approximately .24 cm. (.093") on center.
It should be noted that widely spaced ~tems having small `-7 heads will tend to require smaller engagement and disengagement forces, whereas closely spaced stems having large heads will require larger engagement and 10 disengagement forces.
After base mold 102, sacrificial stem mold lOo and head mold 104 have been properly aligned and secured together in a manner known in the art, a suitable molten plastic material may be injected through inlet passageway 108 to form fastener member 110, as shown in Figure 6. As used herein, "plastic" includes all mon~mers, polymers, and oligomers and mixtures thereof. Injection molding is preferred manner of forming the fastener member of the present invention, because resins with higher melting 20 points may be used to form the fastener member when it is injection molded than when the stems must be heated to form heads atop individual monofilaments according to the prior art. For example, polypropylene may be used to form fastener members by the prior art method of heating the 25 monofilament stems, because it has a relatively low melting point and the ends of the stems are more easily heated to form the heads. Resins such as nylon, however, may be less desirable for the prior art method because nylon has a higher melting temperature, and it may 30 therefore be more difficult to control the formation of a head atop a monofilament by heating. With the method of the present invention, nylon (and other materials that have relatively high melting points) may be used to form the fastener member by injection molding, which may 35 produce a stronger fastener.
Alternatively, a process known as reaction-injection molding (RIM) has also been shown to have utility, and generally involves supplying and mixing the proper reactive liquid components and injecting them into a mold where the mixture is polymerized to form a plastic article. Materials such as polyurethane, polyester and nylon may be reaction-injection molded in accordance with the present invention.
The type of material selected to form the fastener member (hereinafter "fastener material") depends upon the application, and materials such as polypropylene (e.a. product ~ 8826J avai~a~le from Mitsubishi-kasai), -`
polyacetal (e.~. product~'M90-44 available from Polyplastic), nylon (e.q. product ~ 1220S available from Asahi-kasei), ionomer (e.a. product ~ 1554 available from Mitusi DuPont Chemical), and thermocurable plastics such as phenolic resins and polyurethane resins have been shown to have utility. The fastener material should ~ot chemically interact with the stem mold material or otherwise detrimentally affect the structure or -- performance of the sacrificial stem mold. Furthermore, as ~;
noted above, the stem mold material should be resistant to the injection molding process used to form the fastener member.
The following data illustrate several nonlimiting sample parameters of the molding step of the present invention.
I . j , .- . .
Stem Polypro Poly-Ionomer Nylon l Mold pylene acetal 66 I _ .
¦Resin 190 C 190 C 160 C 190 C 260 C
¦Temp.
I _ ._ ¦Max. 1200 1200 1200 1200 1200 ¦Press. kg/cm2 kg/cm2 kg/cm2 kglcm kg/cm2 ¦Molding 30 sec 30 sec 25 sec 30 sec 30 sec I I
co~ ~S -c IS ~-~ lO ~o lS ~-~ lS ~-~
W093/22l20 -i5- PCT~US93/02~42 These samples were run on an Auto Shot C series Model 30A injection molding machine available from Fanuc Co. Ltd. of Tokyo, Japan. The resin was injected into the mold at a flow rate of 10-50 mm/second, and the pressure 5 was limited to a maximum of 1200 kg/cm2. The mold locking -force was approximately 30 tons.
The newly formed fastener is typ~cally allowed to harden while within the base, stem and head molds.
Under some circumstances, the fastener material may cure more quickly or effectively if heat is applied. Base mold 102 and head mold 104 are removed when fastener member 110 has hardened, which leaves sacrificial stem mold 100 attached to the stems of the fastener member, as shown in Figure 7. Sacrificial stem mold 100 is then removed to release fastener member 110 from the stem mold, as illustrated in Figure 8. In the preferred embodiment, the sacrificial stem mold is removed by the application of a solvent, prefera~ly water, to the sacrificial mold material to dissolve the sacrificial mold. In the most preferred embodiment, the sacrificial stem mold is removed by dissolving it with hot water. Mechanical or ultrasonic vibration, preferably in combination with a solvent, but perhaps without the solvent, may expedite the removal of sacrificial stem mold from fastener 110.
To engage opposed fastener members, which may be formed by dividing a single fastener member into two parts, the fastener members are aligned as shown with respect to the prior art in Figure l. Compressive force applied to the respective bases tends to interengage the fastener members, as ~hown in Figure 2 with respect to the prior art. As explained previously, the level of force -~
neceæsary to engage and disengage the fastener members can be controlled by altering the dimensions and spacing of the stems and heads.
- 35 It is believed that, for certain geometries, the force required to di~engage the fastener members constructed acco-ding to the present invention may be much greater (e.~. two times greater) than that required to '~133650 ~
WO93122120 - -16- PCT/US93/02~
separate comparabIe f~steners constructed according to the method of the prior art. Thus the present invention provides greater control over the formation of the shape of the heads, resulting in a fastener that exhibits greater holding power. It is further believed that the force required to engage the fastener member of the present invention may be higher than the force reguired to engage comparable fastener memb~ers formed according to the method of the prior art, altb~ugh it is believed that such engagement forces may be con`trolled by varying the head shape, stem spacing and rèsin modulus.
The present invention has now been described with reference to several embodiments thereof. It will be apparent to those skilled in the art that many changes can -~-15 be made in the embodiments described without departing ~;
from the scope of the invention. Thus, the scope of the present invention should not be limited to the structures described herein, but only by structures described by the language of the claims and the equivalents of those -~
structures.
.
Claims (19)
1. A method of making a fastener member comprising a base (114) and a plurality of arranged stems (118) each having a proximal end projecting from the base and a distal end having a head (120), the method comprising the steps of:
(a) providing a permanent base mold (102) having a cavity (109) adapted to mold the base of the fastener;
(b) providing a sacrificial stem mold (100) having a plurality of arranged passageways (106) for molding the stems;
(c) providing a permanent head mold (104) having a plurality of arranged cavities for molding the heads;
(d) securing the sacrificial stem mold adjacent the base mold with the passageways of the stem mold in fluidic communication with the base mold cavity, and securing the head mold adjacent the sacrificial stem mold with the head mold cavities in fluidic communication with the passageways of the sacrificial stem mold;
(e) flowing a molten plastic into the molds through an inlet passageway (108) in one of the base mold, the sacrificial stem mold, and the head mold to form the base, stems, and heads of the fastener member;
(f) solidifying the plastic within the molds to form the fastener member;
(g) separating the head mold and the base mold from the sacrificial stem mold and the solidified fastener member; and (h) removing the sacrificial mold to release the fastener member from the sacrificial mold without damage to the fastener member.
(a) providing a permanent base mold (102) having a cavity (109) adapted to mold the base of the fastener;
(b) providing a sacrificial stem mold (100) having a plurality of arranged passageways (106) for molding the stems;
(c) providing a permanent head mold (104) having a plurality of arranged cavities for molding the heads;
(d) securing the sacrificial stem mold adjacent the base mold with the passageways of the stem mold in fluidic communication with the base mold cavity, and securing the head mold adjacent the sacrificial stem mold with the head mold cavities in fluidic communication with the passageways of the sacrificial stem mold;
(e) flowing a molten plastic into the molds through an inlet passageway (108) in one of the base mold, the sacrificial stem mold, and the head mold to form the base, stems, and heads of the fastener member;
(f) solidifying the plastic within the molds to form the fastener member;
(g) separating the head mold and the base mold from the sacrificial stem mold and the solidified fastener member; and (h) removing the sacrificial mold to release the fastener member from the sacrificial mold without damage to the fastener member.
2. The method of claim l, wherein step (h) includes removing the sacrificial mold by dissolving the mold with a solvent.
3. The method of claim 1, wherein step (h) includes removing the sacrificial mold by providing a heated solvent and dissolving the mold with the heated solvent.
4. The method of claim 2, wherein the solvent comprises water.
5. The method of claim 3, wherein the solvent comprises water.
6. The method of claim 2, wherein step (h) includes removing the sacrificial mold by dissolving the mold with a solvent and agitating the mold.
7. The method of claim 1, wherein step (e) includes the step of injection molding the fastener member.
8. The method of claim 1, wherein step (e) includes the step of reaction-injection molding the fastener member.
9. A fastener member made by a process including the steps of:
(a) providing a permanent base mold (102) having a cavity (109) adapted to mold the base of the fastener;
(b) providing a sacrificial stem mold (100) having a plurality of arranged passageways (106) for molding the stems;
(c) providing a permanent head mold (104) having a plurality of arranged cavities for molding the heads;
(d) securing the sacrificial stem mold adjacent the base mold with the passageways of the stem mold in fluidic communication with the base mold cavity, and the head mold adjacent the sacrificial stem mold with the head mold cavities in fluidic communication with the passageways of the sacrificial stem mold;
(e) flowing a molten plastic into the molds through an inlet passageway (108) in one of the base mold, the sacrificial stem mold, and the head mold to form the base, stems, and heads of the fastener member;
(f) solidifying the plastic within the molds to form the fastener member;
(g) separating the head mold and the base mold from the sacrificial stem mold and the solidified fastener member; and (h) removing the sacrificial mold to release the fastener member from the sacrificial mold without damage to the fastener member .
(a) providing a permanent base mold (102) having a cavity (109) adapted to mold the base of the fastener;
(b) providing a sacrificial stem mold (100) having a plurality of arranged passageways (106) for molding the stems;
(c) providing a permanent head mold (104) having a plurality of arranged cavities for molding the heads;
(d) securing the sacrificial stem mold adjacent the base mold with the passageways of the stem mold in fluidic communication with the base mold cavity, and the head mold adjacent the sacrificial stem mold with the head mold cavities in fluidic communication with the passageways of the sacrificial stem mold;
(e) flowing a molten plastic into the molds through an inlet passageway (108) in one of the base mold, the sacrificial stem mold, and the head mold to form the base, stems, and heads of the fastener member;
(f) solidifying the plastic within the molds to form the fastener member;
(g) separating the head mold and the base mold from the sacrificial stem mold and the solidified fastener member; and (h) removing the sacrificial mold to release the fastener member from the sacrificial mold without damage to the fastener member .
10. A mold for making a unitary plastic fastener member comprising a base (114) and a plurality of stems (118) arranged in columns and rows, each stem having a proximal end projecting from said base and a distal end having a head (120), the mold comprising:
(a) a permanent base mold (102) having a cavity (109) adapted to mold the base of the fastener, said base mold having an inlet passageway (108) communicating said cavity with an outer wall of said base mold and adapted for transfer of a molten plastic material to said cavity to form the base of the fastener member;
(b) a sacrificial stem mold (100) adjacent said base mold and having a plurality of passageways (106) arranged in columns and rows and in fluidic communication with said base mold cavity, said head mold cavities adapted to receive said molten plastic material from said base mold cavity, and to mold the stems atop and projecting from the base; and (c) a permanent head mold (104) having a plurality of cavities arranged in columns and rows and in fluidic communication with said sacrificial stem mold passageways, said head mold cavities adapted to receive said molten plastic material from said passageways of said sacrificial stem mold to mold the heads of the fastener member;
said base mold and head mold adapted for separation from said sacrificial stem mold and plastic fastener member to enable release of the fastener member from said sacrificial stem mold without damage thereto.
(a) a permanent base mold (102) having a cavity (109) adapted to mold the base of the fastener, said base mold having an inlet passageway (108) communicating said cavity with an outer wall of said base mold and adapted for transfer of a molten plastic material to said cavity to form the base of the fastener member;
(b) a sacrificial stem mold (100) adjacent said base mold and having a plurality of passageways (106) arranged in columns and rows and in fluidic communication with said base mold cavity, said head mold cavities adapted to receive said molten plastic material from said base mold cavity, and to mold the stems atop and projecting from the base; and (c) a permanent head mold (104) having a plurality of cavities arranged in columns and rows and in fluidic communication with said sacrificial stem mold passageways, said head mold cavities adapted to receive said molten plastic material from said passageways of said sacrificial stem mold to mold the heads of the fastener member;
said base mold and head mold adapted for separation from said sacrificial stem mold and plastic fastener member to enable release of the fastener member from said sacrificial stem mold without damage thereto.
11. The mold of claim 10, wherein said sacrificial mold is made of a thermoplastic containing a COOH group that is soluble in an aqueous media.
12. The mold of claim 10, wherein said arranged cavities are generally hemispherical.
13. The mold of claim 10 r wherein said arranged cavities are generally shaped as mushroom heads.
14. A mold for making a unitary plastic fastener member comprising a base and a plurality of stems arranged in columns and rows, each stem having a proximal end projecting from said base and a distal end having a head, the mold comprising:
(a) a permanent base mold having a cavity 1109) adapted to mold the base of the fastener;
(b) a sacrificial stem mold (100) adjacent said base mold and having a plurality of passageways (106) arranged in columns and rows and in fluidic communication with said base mold cavity to mold the stems atop and projecting from the base; and (c) a permanent head mold (104) having a plurality of cavities arranged in columns and rows and in fluidic communication with said sacrificial stem mold passageways, said head mold cavities adapted to mold the heads of the fastener member, said head mold having an inlet passageway (108') communicating at least one of said cavities with an outer wall of said head mold and adapted for transfer of a molten plastic material to said at least one cavity to form the fastener member;
said base mold and head mold adapted for separation from said sacrificial stem mold and plastic fastener member to enable release of the fastener member from said sacrificial stem mold without damage thereto.
(a) a permanent base mold having a cavity 1109) adapted to mold the base of the fastener;
(b) a sacrificial stem mold (100) adjacent said base mold and having a plurality of passageways (106) arranged in columns and rows and in fluidic communication with said base mold cavity to mold the stems atop and projecting from the base; and (c) a permanent head mold (104) having a plurality of cavities arranged in columns and rows and in fluidic communication with said sacrificial stem mold passageways, said head mold cavities adapted to mold the heads of the fastener member, said head mold having an inlet passageway (108') communicating at least one of said cavities with an outer wall of said head mold and adapted for transfer of a molten plastic material to said at least one cavity to form the fastener member;
said base mold and head mold adapted for separation from said sacrificial stem mold and plastic fastener member to enable release of the fastener member from said sacrificial stem mold without damage thereto.
15. The mold of claim 14, wherein said sacrificial mold is made of a thermoplastic containing a COOH group that is soluble in an aqueous media.
16. A unitary, integrally molded plastic fastener member comprising a monolithic base (114) having a plurality of stems (118) projecting therefrom and arranged in a plurality of columns and a plurality of rows, each stem having a head formed at a distal end of said stem.
17. The fastener member of claim 16, wherein said fastener member further includes a secondary fastening portion (111) integrally molded thereto.
18. The fastener member of claim 16, wherein each head is hemispherically shaped.
19. The fastener member of claim 16, wherein each head is conically shaped.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US07/880,052 US5242646A (en) | 1992-05-07 | 1992-05-07 | Method of making an interengaging fastener member |
| US07/880,052 | 1992-05-07 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2133650A1 true CA2133650A1 (en) | 1993-11-11 |
Family
ID=25375420
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002133650A Abandoned CA2133650A1 (en) | 1992-05-07 | 1993-03-29 | Interengaging fastener member and method of making same |
Country Status (10)
| Country | Link |
|---|---|
| US (2) | US5242646A (en) |
| EP (1) | EP0640033B1 (en) |
| JP (1) | JP3318332B2 (en) |
| KR (2) | KR100272823B1 (en) |
| CA (1) | CA2133650A1 (en) |
| DE (1) | DE69311107T2 (en) |
| ES (1) | ES2102650T3 (en) |
| MX (1) | MX9302385A (en) |
| TW (1) | TW218370B (en) |
| WO (1) | WO1993022120A1 (en) |
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| US4894060A (en) * | 1988-01-11 | 1990-01-16 | Minnesota Mining And Manufacturing Company | Disposable diaper with improved hook fastener portion |
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| US4889666A (en) * | 1988-09-06 | 1989-12-26 | Kabushiki-Kaisha Yamau | Method for producing concrete products provided with inlaid patterns |
| JPH02134012A (en) * | 1988-11-15 | 1990-05-23 | Alpine Electron Inc | Radio receiver |
| JPH0355716U (en) * | 1989-10-03 | 1991-05-29 | ||
| US5058245A (en) * | 1989-10-31 | 1991-10-22 | Kuraray Co., Ltd. | Fastening device and method for fixing adherend by using the same |
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| US5140727A (en) * | 1990-03-09 | 1992-08-25 | Dowbrands L.P. | Zipper for reclosable thermoplastic bag, process and apparatus for making |
| US5040275A (en) * | 1990-06-01 | 1991-08-20 | Minnesota Mining And Manufacturing Company | Strip material used for forming fasteners |
| US5149573A (en) * | 1990-06-01 | 1992-09-22 | Minnesota Mining And Manufacturing Company | Highly transparent strip material used for forming fasteners |
| JPH04123106A (en) * | 1990-09-12 | 1992-04-23 | Murata Mach Ltd | Controller for nc machine tool |
| US5077870A (en) * | 1990-09-21 | 1992-01-07 | Minnesota Mining And Manufacturing Company | Mushroom-type hook strip for a mechanical fastener |
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| US5242646A (en) * | 1992-05-07 | 1993-09-07 | Minnesota Mining And Manufacturing Company | Method of making an interengaging fastener member |
| JPH0613321A (en) * | 1992-06-24 | 1994-01-21 | Seiko Epson Corp | Forming method for silicon thin film |
| JPH0613322A (en) * | 1992-06-25 | 1994-01-21 | Rikagaku Kenkyusho | Forming apparatus for hetero structure |
| JP2744384B2 (en) * | 1992-07-22 | 1998-04-28 | ワイケイケイ株式会社 | Method and apparatus for manufacturing engaging member having back member on back surface |
| JP3392887B2 (en) * | 1992-10-16 | 2003-03-31 | ミネソタ マイニング アンド マニュファクチャリング カンパニー | Interlocking fastener |
| JP3407322B2 (en) * | 1993-01-26 | 2003-05-19 | 株式会社ニフコ | Hook-and-loop fastener |
-
1992
- 1992-05-07 US US07/880,052 patent/US5242646A/en not_active Expired - Lifetime
- 1992-06-23 TW TW081104931A patent/TW218370B/zh active
-
1993
- 1993-03-29 ES ES93912096T patent/ES2102650T3/en not_active Expired - Lifetime
- 1993-03-29 EP EP93912096A patent/EP0640033B1/en not_active Expired - Lifetime
- 1993-03-29 DE DE69311107T patent/DE69311107T2/en not_active Expired - Lifetime
- 1993-03-29 CA CA002133650A patent/CA2133650A1/en not_active Abandoned
- 1993-03-29 WO PCT/US1993/002942 patent/WO1993022120A1/en active Application Filing
- 1993-03-29 KR KR1019940703919A patent/KR100272823B1/en not_active IP Right Cessation
- 1993-03-29 JP JP51926093A patent/JP3318332B2/en not_active Expired - Fee Related
- 1993-04-23 MX MX9302385A patent/MX9302385A/en unknown
-
1996
- 1996-02-28 US US08/608,221 patent/US5614232A/en not_active Expired - Lifetime
-
2000
- 2000-03-14 KR KR1020000012734A patent/KR100273083B1/en not_active IP Right Cessation
Also Published As
| Publication number | Publication date |
|---|---|
| KR100273083B1 (en) | 2000-11-15 |
| KR950701270A (en) | 1995-03-23 |
| MX9302385A (en) | 1993-11-01 |
| US5614232A (en) | 1997-03-25 |
| JP3318332B2 (en) | 2002-08-26 |
| EP0640033A1 (en) | 1995-03-01 |
| ES2102650T3 (en) | 1997-08-01 |
| JPH07509668A (en) | 1995-10-26 |
| US5242646A (en) | 1993-09-07 |
| EP0640033B1 (en) | 1997-05-28 |
| DE69311107D1 (en) | 1997-07-03 |
| TW218370B (en) | 1994-01-01 |
| WO1993022120A1 (en) | 1993-11-11 |
| KR100272823B1 (en) | 2000-11-15 |
| DE69311107T2 (en) | 1998-01-22 |
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| Date | Code | Title | Description |
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| FZDE | Dead |