Rigid subtrates having molded projections, and methods of making the same
First Claim
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1. A method of molding projections on a substrate, the method comprising:
- introducing a substrate having an outer surface into a gap formed between a peripheral surface of a rotating mold roll and a supporting surface, the mold roll defining a plurality of discrete cavities that extend inwardly from the peripheral surface of the rotating mold roll;
delivering a resin to a nip formed between the outer surface of the substrate and the peripheral surface of the rotating mold roll, the outer surface of the substrate and the peripheral surface of the rotating mold roll being arranged to generate sufficient pressure to at least partially fill the cavities in the mold roll as the substrate is moved through the gap to mold an array of discrete projections comprising stems extending integrally from a layer of the resin bonded to the substrate; and
then withdrawing the molded projections from their respective cavities by separation of the peripheral surface of the mold roll from the outer surface of the substrate by continued rotation of the mold roll, wherein the substrate has a beam stiffness, measured as a product of an overall moment of inertia of a nominal transverse cross-section and an effective modulus of elasticity of a material from which the substrate is formed, that is greater than about 200 lb-in2 (0.574 N-m2).
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Abstract
Rigid substrates having molded fastener projections, and methods of making the same are disclosed. A substrate has a beam stiffness, measured as a product of an overall moment of inertia of a nominal transverse cross-section and an effective modulus of elasticity of a material from which the substrate is made, that is greater than about 200 lb-in2 (0.574 N-m2).
58 Citations
24 Claims
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1. A method of molding projections on a substrate, the method comprising:
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introducing a substrate having an outer surface into a gap formed between a peripheral surface of a rotating mold roll and a supporting surface, the mold roll defining a plurality of discrete cavities that extend inwardly from the peripheral surface of the rotating mold roll;
delivering a resin to a nip formed between the outer surface of the substrate and the peripheral surface of the rotating mold roll, the outer surface of the substrate and the peripheral surface of the rotating mold roll being arranged to generate sufficient pressure to at least partially fill the cavities in the mold roll as the substrate is moved through the gap to mold an array of discrete projections comprising stems extending integrally from a layer of the resin bonded to the substrate; and
thenwithdrawing the molded projections from their respective cavities by separation of the peripheral surface of the mold roll from the outer surface of the substrate by continued rotation of the mold roll, wherein the substrate has a beam stiffness, measured as a product of an overall moment of inertia of a nominal transverse cross-section and an effective modulus of elasticity of a material from which the substrate is formed, that is greater than about 200 lb-in2 (0.574 N-m2). - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21)
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22. A method of molding projections on a substrate, the method comprising:
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introducing a linear substrate having an outer surface into a gap formed between a peripheral surface of a rotating mold roll and a supporting surface, the mold roll defining a plurality of discrete cavities that extend inwardly from the peripheral surface of the rotating mold roll;
delivering a resin to a nip formed between the outer surface of the substrate and the peripheral surface of the rotating mold roll, the outer surface of the substrate and the peripheral surface of the rotating mold roll being arranged to generate sufficient pressure to at least partially fill the cavities in the mold roll as the substrate is moved through the gap to mold an array of discrete projections comprising stems extending integrally from a layer of the resin bonded to the substrate; and
thenwithdrawing the molded projections from their respective cavities by separation of the peripheral surface of the mold roll from the outer surface of the substrate by continued rotation of the mold roll, wherein the substrate has a beam stiffness sufficiently great that during withdrawal of the molded projections from their respective cavities, the substrate remains substantially linear. - View Dependent Claims (23)
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24. An article having molded fastening projections comprising:
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a substrate; and
an array of discrete molded projections comprising stems extending outwardly from and integral with a molded layer of resin solidified about surface features of the substrate and thereby securing the projections directly to the substrate, wherein the substrate has a beam stiffness, measured as a product of an overall moment of inertia of a nominal transverse cross-section and an effective modulus of elasticity of a material from which the substrate is made, that is greater than about 200 lb-in2 (0.574 N-m2).
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Specification