Stackable mold plates having arrays of laser-cut mold surfaces at their edges

• US 6,039,556 A
• Filed: 09/10/1997
• Issued: 03/21/2000
• Est. Priority Date: 01/21/1997
• Status: Expired due to Term

• Current Assignee: Velcro BVBA
• Original Assignee: Velcro Industries BV (Chartwell Industries Ltd)
• Inventors: Formato, Richard M., Harvey, Andrew C., Jens, Stephen C.
• Primary Examiner(s): Mackey, James P.
• Application Number:
  US08/926,517
• Time in Patent Office: 923 Days
• Field of Search: 425/113, 425/192 R, 425/194, 425/237, 425/363, 425/814, 425/470, 425/471, 24/442, 24/452
• US Class Current: 425/363
• CPC Class Codes: A44B 18/0049 obtained by moulding processes compression moulding or articles of indefinite length characterised by the shape of the surface B29C43/222; screen moulding B29C67/08
• CPC Class Codes: B29C 2035/1616 using liquids
• CPC Class Codes: B29C 2043/461 the rollers having specific surface features
• CPC Class Codes: B29C 2043/465 having one or more cavities, e.g. for forming distinct products
• CPC Class Codes: B29C 33/0027 with deep narrow cavities, e.g. for making piles non-woven pile fabrics D04H11/00
• CPC Class Codes: B29C 33/044 in rolls calenders or drums
• CPC Class Codes: B29C 33/301 Modular mould systems [MMS], i.e. moulds built up by stacking mould elements, e.g. plates, blocks, rods B29C33/0088 takes precedence
• CPC Class Codes: B29C 43/222 characterised by the shape of the surface
• CPC Class Codes: B29C 43/46 Rollers
• CPC Class Codes: B29L 2031/729 Hook and loop-type fasteners
• CPC Class Codes: F28F 5/02 Rotary drums or rollers
• CPC Class Codes: Y10S 425/814 Zipper
• CPC Class Codes: Y10T 24/27 including readily dissociable fastener having numerous, protruding, unitary filaments randomly interlocking with, and simultaneously moving towards, mating structure [e.g., hook-loop type fastener]
• CPC Class Codes: Y10T 24/2792 having mounting surface and filaments constructed from common piece of material
• CPC Class Codes: Y10T 29/49554 Work contacting surface having annular axial sections
• CPC Class Codes: Y10T 29/49556 Work contacting surface element assembled to end support members
• CPC Class Codes: Y10T 29/49899 by multiple cooperating aligning means
• CPC Class Codes: Y10T 29/49901 Sequentially associating parts on stationary aligning means

Abstract

Molding apparatus and method for molding of features integral with a base, such as in the production of fastener elements for hook-and-loop type touch fasteners, e.g. by the Fischer process, employs a mold roll formed of rings that have coolant passages formed within the ring components themselves for substantially direct contact with cooling liquid. Axial tie rods compress the mold rings together, contributing to the sealing of the coolant passages and the stiffness of the mold roll. Other types of sealing are disclosed. Mold cavities, including cavities used for injection molding, and cooling passages formed in either mold rings or injection mold plates by photo-chemical etching, laser machining and other techniques are disclosed. Various machines and methods taking unique advantage of these features are disclosed, including ring alignment methods.

Claims

1. A mold plate formed from flat plate stock, having an array of laser-cut mold surfaces at an edge of the mold plate for forming, together with cooperating surfaces, molding cavities shaped to form respective molded fastener elements of a touch fastener product,

at least many of the mold surfaces each forming a point, extending into material of the plate, having a radius of less than about 0.001 inch.

2. The mold plate of claim 1 having coolant holes extending through the thickness of the mold plate.

3. The mold plate of claim 1 having a thickness of less than about 0.020 inch.

4. The mold plate of claim 1 wherein said mold surfaces are concave and extend through only a portion of the thickness of the mold plate.

5. The mold plate of claim 1 wherein said mold surfaces forming said points extend fully through the thickness of the mold plate.

7. The mold plate of claim 1 wherein said many of the mold surfaces are shaped to form fastener elements for touch fasteners, said radius defining an end radius of a fastener element feature.

8. The mold plate of claim 7 wherein said mold surfaces form hook-shaped molding cavities.

9. The mold plate of claim 1 wherein said radius is less than about 0.0005 inch.

10. The mold plate of claim 1 further defining an array of mounting holes and an array of coolant holes, the coolant holes being of smaller diameter than, and of closer proximity to the mold surfaces than, the mounting holes.

11. The mold plate of claim 1 of circular form, said edge forming a circumference of the mold plate.

12. The mold plate of claim 11 having a thickness of less than about 0.020 inch and a diameter on the order of 8 to 12 inches.

13. The mold plate of claim 4 defining said mold surfaces on both of two broad sides thereof.

14. The mold plate of claim 1 wherein said mold surfaces have a surface roughness of about 63 microinches.

6. A mold plate, formed from flat plate stock, having an array of laser-cut mold surfaces at a peripheral edge of the mold-plate, and laser-cut coolant holes at locations spaced from said edge, said mold surfaces and coolant holes extending fully through the thickness of the mold plates,

at least many of the mold surfaces each forming a point, extending into material of the plate, having a radius of less than about 0.001 inch.

15. A flat mold plate having a thickness of less than about 0.020 inch and defining an array of mold surfaces shaped to form respective molded fastener elements of a touch fastener product, the mold surfaces located at a peripheral edge of the mold plate,

at least many of the mold surfaces each defining a point, extending into material of the plate, having a radius of less than about 0.001 inch for forming a sharp tip of a fastener element.

16. The flat mold plate of claim 15 of circular form, the array of mold surfaces spaced along a circumferential edge of the mold plate.

17. The flat mold plate of claim 15 wherein the mold surfaces are shaped to form hook-shaped fastener elements, each hook-shaped fastener element having a sharp distal tip.

18. The flat mold plate of claim 15 wherein said mold surfaces defining said points extend fully through the thickness of the mold plate.

19. The flat mold plate of claim 15 wherein the mold surfaces are shaped to form fastener elements of less than about 0.020 inch in height.