Continuous molding of fastener products and the like and products produced thereby

Abstract

Improvements are disclosed for an apparatus for continuously molding small fastener elements integral with a base web from a flowable resin. The apparatus comprises a cylindrical mold roll rotatable about an axis and defining small fastener element-shaped mold cavities in the surface thereof, and pressure-applying means to apply operating pressure to force the resin into the cavities at a pressure zone. The pressure-applying means and mold roll define a mold gap therebetween for forming the base web. The advantageous use of relatively long mold rolls, to produce a correspondingly wide web, and the use of higher molding pressures, e.g. to form very small fastener elements, is enabled by various improvements, including means to maintain the mold gap at a desired thickness profile across the length of the molding region of the mold roll under operating pressure. In some cases the pressure-applying means includes a pressure roll, in other cases it includes a resin nozzle assembly or pressure head. In some other cases it includes a belt. Various control schemes are also disclosed, as are means to provide cooling. In some particularly useful embodiments, at least one of the rolls of the apparatus has a resiliently deformable surface. Methods of molding fastener elements directly on a sheet material, such as sandpaper, are also disclosed, as well as methods for laminating.

1 - 59 . (canceled)  
     
     
         60 . A method of forming a fastener product that includes a plurality of fastener elements integral with a base layer, the method comprising: 
 providing a rotatable mold roll having an outer surface and a plurality of inwardly extending cavities shaped to form at least stem portions of the fastener elements;    depositing molten resin on the outer surface of the cavity roll with an applicator; and    by rotation of the mold roll, carrying the molten resin on the mold roll a distance from a point at which the resin is deposited, into a pressure region in which pressure fills the inwardly extending cavities with some of the resin, other of the resin forming the base layer on the outer surface of the cavity roll.    
     
     
         61 . The method of  claim 60 , wherein the mold roll is cooled.  
     
     
         62 . The method of  claim 60 , wherein the applicator generates sufficient pressure to partially fill the cavities.  
     
     
         63 . The method of  claim 60 , wherein the resin is under substantially atmospheric pressure conditions as it is carried from the applicator toward the pressure region.  
     
     
         64 . The method of  claim 60 , wherein the cavities are shaped to form elements that are loop-engageable.  
     
     
         65 . The method of  claim 60 , wherein the cavities are shaped to form hooks.  
     
     
         66 . The method of  claim 60 , including introducing a web material to the pressure region, pressure in the pressure region bonding the web material to the resin to form a fastener laminate.  
     
     
         67 . The method of  claim 60 , wherein the pressure in the pressure region is from about 1000 to about 1600 pounds per lineal inch along the mold roll.  
     
     
         68 . The method of  claim 60 , wherein the mold roll includes an axially arranged stack of disks, some having mold cavities at their peripheral surfaces.  
     
     
         69 . The method of  claim 60 , wherein the cavities extend into the mold roll to a depth of between about 0.004 and 0.035 inch.