Spunlaced loop material for a refastenable fastening device and methods of making same

Abstract

A loop component for use in a hook and loop fastening system, and methods of making same are provided, wherein a spunlaced fabric having a plurality of loop structures is formed by entangling a plurality of non-interbonded fibers in a fibrous web of material. The loop structures are configured to engage hooks from a hook component having a hook density between about 30 and 400 hooks per square centimeter, and have a peel strength of between about 50 grams and 2000 grams. The spunlaced fabric may include a backing layer.

1 . A loop component for use in a hook and loop fastening system, comprising a spunlaced fabric having a plurality of loop structures formed only by entangling a plurality of non-interbonded fibers in a fibrous web of material without a backing layer.  
     
     
         2 . The loop component of  claim 1 , wherein the loop structures of the spunlaced fabric are configured to engage hooks from a hook component having a hook density between about 30 and 400 hooks per square centimeter.  
     
     
         3 . The loop component of  claim 1 , wherein the loop structures of the spunlaced fabric are configured to engage hooks from a hook component having individual hook lengths of 0.8 cm or less.  
     
     
         4 . The loop component of  claim 1 , wherein the loop structures of the spunlaced fabric have an average peel strength of between about 50 grams and 550 grams when tested using ASTM D5170-98 test method.  
     
     
         5 . The loop component of  claim 1 , wherein the loop structures of the spunlaced fabric have an average maximum load peel strength of between about 100 grams and 2,000 grams when tested using ASTM D5170-98 test method.  
     
     
         6 . The loop component of  claim 1 , wherein the loop structures of the spunlaced fabric have an average peak shear strength of between about 1,000 and 15,000 grams when tested using ASTM D5169-91 test method.  
     
     
         7 . The loop component of  claim 1 , wherein the loop structures of the spunlaced fabric maintain a maximum average peel strength after 20 test cycles between about 50 and 550 grams when tested using ASTM D5170-98 test method.  
     
     
         8 . The loop component of  claim 1 , wherein the fibers of the spunlaced fabric have a denier of between about 0.5 and 19.  
     
     
         9 . The loop component of  claim 1 , wherein the fibers of the spunlaced fabric have a density of between about 0.1 and 1.2 grams per cubic centimeter.  
     
     
         10 . The loop component of  claim 1 , wherein the spunlaced fabric has a thickness of between about 10 and 95 mils.  
     
     
         11 . The loop component of  claim 1 , wherein the non-interbonded fibers of the fibrous web comprise fibers selected from the group consisting of polypropylene, polyethylene, polyethylene terephthalate, polyester, acetate, nylon, viscose and acrylic, or blends or bicomponents thereof.  
     
     
         12 . The loop component of  claim 1 , wherein the spunlaced fabric comprises homogenous spunlaced fabric.  
     
     
         13 . The loop component of  claim 1 , wherein the spunlaced fabric comprises randomly oriented fibers.  
     
     
         14 . The loop component of  claim 1 , wherein the spunlaced fabric comprises substantially aligned fibers.  
     
     
         15 . The loop component of  claim 1 , wherein the spunlaced fabric comprises apertured spunlaced fabric.  
     
     
         16 . The loop component of  claim 1 , wherein the spunlaced fabric comprises two or more layers of fibrous material.  
     
     
         17 . The loop component of  claim 1 , wherein the spunlaced fabric is formed from a fibrous web via air laying.  
     
     
         18 . The loop component of  claim 1 , wherein the spunlaced fabric is formed from a fibrous web via carding.  
     
     
         19 . The loop component of  claim 1 , wherein the spunlaced fabric is embossed with a decorative pattern.  
     
     
         20 . The loop component of  claim 19 , wherein the decorative pattern comprises elements having dimensions between about 0.02 mm and 4 mm.  
     
     
         21 - 52 . (canceled)  
     
     
         53 . A hook and loop fastening system, comprising: 
 a hook component having a hook density between about 30 and 400 hooks per square centimeter; and    a loop component, comprising a spunlaced fabric having a plurality of loop structures formed only by entangling a plurality of non-interbonded fibers in a fibrous web of material without a backing layer, wherein the loop structures of the spunlaced fabric are configured to engage hooks from the hook component.    
     
     
         54 . The hook and loop fastening system of  claim 53 , wherein the loop structures of the spunlaced fabric are configured to engage hooks having individual hook lengths of 0.8 cm or less.  
     
     
         55 . The hook and loop fastening system of  claim 53 , wherein the loop structures of the spunlaced fabric have an average peel strength of between about 50 grams and 550 grams when tested using ASTM D5170-98 test method.