Methods of producing fastener products

Abstract

A method of producing a fastener product having a multiplicity of fastener elements extending from a base. The method includes introducing molten resin to the circumferential surface of the mold roll under pressure conditions and forcing some of the resin into molding cavities to mold an array of fastener elements integrally with resin disposed at the circumferential surface of the mold roll.

1 . A method of producing a fastener product having a multiplicity of fastener elements extending from a base, the method comprising: 
 providing a mold roll having a circumferential surface defining an array of apertures therein, the apertures extending inward from the circumferential surface;    disposing inserts within the apertures, the inserts having surfaces at least partially defining blind molding cavities;    introducing molten resin to the circumferential surface of the mold roll under pressure conditions and forcing some of the resin into the molding cavities to mold an array of fastener elements integrally with resin disposed at the circumferential surface of the mold roll; and then stripping the resin from the mold roll.    
   
   
       2 . The method of  claim 1 , wherein the resin is introduced into a nip defined by the mold roll and an adjacent pressure device.  
   
   
       3 . The method of  claim 2 , wherein the pressure device comprises a counter-rotating pressure roll.  
   
   
       4 . The method of  claim 2 , wherein the pressure device comprises an extruder that extrudes the resin into the nip.  
   
   
       5 . The method of  claim 3 , wherein the nip is defined by the mold roll and an arcuate shaped housing of the extruder.  
   
   
       6 . The method of  claim 1 , wherein the molding cavities are completely defined within the inserts.  
   
   
       7 . The method of  claim 6 , wherein multiple molding cavities are completely defined within each insert.  
   
   
       8 . The method of  claim 1 , wherein first molding cavities are defined between first sides of the inserts and the mold roll.  
   
   
       9 . The method of  claim 8 , wherein second molding cavities are defined between second sides of the inserts and the mold roll.  
   
   
       10 . The method of  claim 1 , wherein the inserts comprise an upper portion and a lower portion, the lower portion including a first segment extending transversely beyond a first side of the mold roll and a second segment extending transversely beyond a second side of the mold roll.  
   
   
       11 . The method of  claim 9 , further comprising securing a first retainer cap to the first side of the mold roll, and securing a second retainer cap to the second side of the mold roll, the retainer caps having inner portions conforming to the first and second segments of the inserts to retain the inserts within the apertures.  
   
   
       12 . The method of  claim 1 , wherein the mold roll comprises a sleeve having an inner surface, the array of apertures extending from the inner surface to the circumferential surface of the sleeve.  
   
   
       13 . The method of  claim 12 , wherein the molding cavities are defined by perimeter portions of the inserts and the mold roll.  
   
   
       14 . The method of  claim 13 , wherein multiple molding cavities are defined by the perimeter portion of each insert and the mold roll.  
   
   
       15 . The method of  claim 12 , further comprising disposing the sleeve around a mandrel to retain the inserts within the apertures.  
   
   
       16 . The method of  claim 15 , wherein bottom surfaces of the inserts are shaped to conform to the mandrel.  
   
   
       17 . The method of  claim 1 , further comprising configuring the inserts within the apertures in any of a plurality of orientations.  
   
   
       18 . The method of  claim 17 , wherein the molding cavities include crook portions.  
   
   
       19 . The method of  claim 18 , wherein the inserts are configured such that substantially all of the crook portions face in substantially the same direction.  
   
   
       20 . The method of  claim 18 , wherein substantially all of the crook portions face in a direction transverse to the mold roll.