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US 7,156,937 B2Granted
Needling through carrier sheets to form loops
AssigneeVelcro Industries B.V.
InventorsGeorge A. Provost, William H. Shepard
Life of this patent
Estimating the term…
Abstract
A loop fastener product is formed by needling a batt of fibers through a carrier sheet such as a plastic film, to form loops on the other side of the carrier sheet. A binder, such as a powder resin or plastic film, is placed over the fiber side of the product and fused to the carrier sheet to bond the fibers in place. In some cases the product is needled in only discrete areas, leaving other areas free of loops. The product may be formed into outer covers for disposable diapers. Fibers of one resin are readily combined with films and backings of other resins to produce particularly thin and low weight loop materials.
Claims92
A method of making a loop fastener product, the method comprising
- placing a layer of fibers against a first side of a carrier sheet of film, the layer of fibers having an overall density of less than about 5 ounces per square yard and the carrier sheet having an overall thickness of less than about 0.005 inch;
- needling fibers of the layer through the carrier sheet by piercing the carrier sheet with forked needles that drag portions of the fibers through holes formed in the carrier sheet during needling, leaving loops of the fibers extending from the holes on a second side of the carrier sheet;
- and
- fusing the fibers to the first side of the carrier sheet to anchor bases of the loops;
- wherein the carrier sheet forms projections extending out of a general plane of the carrier sheet at the holes, the projections bearing against fibers passing through the holes.
2 more elements
A method of making a loop fastener product, the method comprising
- placing a layer of fibers against a first side of a carrier sheet of film;
- needling fibers of the layer through the carrier sheet by piercing the sheet with forked needles that drag portions of the fibers through holes formed in the sheet during needling, leaving loops of the fibers extending from the holes on a second side of the carrier sheet;
- placing a particulate-form binder on the fibers on the first side of the pierced sheet, particles of the binder entering interstices defined between adjacent fibers near the holes in the carrier sheet;
- and then
- fusing the binder to the carrier sheet to anchor bases of the loops wherein the carrier sheet forms projections extending out of a general plane of the carrier sheet at the holes, the projections bearing against fibers passing through the holes.
2 more elements
A method of making a loop fastener product, the method comprising
- placing a layer of fibers against a first side of a carrier sheet of film;
- with a second side of the carrier sheet against a support bed, needling fibers of the layer through the carrier sheet by piercing the sheet with forked needles that drag portions of the fibers through holes formed in the sheet during needling, leaving loops of the fibers extending from the holes into the support bed on a second side of the carrier sheet, wherein the carrier sheet forms projections extending out of a general plane of the carrier sheet at the holes, the projections bearing against fibers passing through the holes;
- placing a binder on the fibers on the first side of the pierced sheet;
- and,
- with the loops extending into the support bed, applying pressure to the first side of the pierced sheet to fuse the binder to the carrier sheet in regions supported by the support bed.
2 more elements
A method of making a lightweight loop fastener product, the method comprising
- placing a layer of fibers against a first side of a carrier sheet of film, the fibers being of between about 2 and 10 denier;
- needling fibers of the layer through the carrier sheet by piercing the sheet with forked needles that drag portions of the fibers through holes formed in the sheet during needling, leaving loops of the fibers extending from the holes on a second side of the carrier sheet, the needles penetrating to a maximum distance of less than about 7.0 millimeters from the first side of the carrier sheet and being of a diameter of less than about 0.036 inch (0.9 millimeter), wherein the carrier sheet forms projections extending out of a general plane of the carrier sheet at the holes, the projections bearing against fibers passing through the holes;
- and
- fusing the fibers to the carrier sheet to anchor bases of the loops.
1 more element
A method of providing hook-engageable loops in selected regions on a carrier sheet, the method comprising
- placing a layer of fibers against a first side of a carrier sheet of film;
- needling fibers of the layer through the carrier sheet in selected regions by piercing the sheet with forked needles that drag portions of the fibers through holes formed in the selected regions of the sheet during needling, leaving loops of the fibers extending from the holes on a second side of the carrier sheet wherein the carrier sheet forms projections extending out of a general plane of the carrier sheet at the holes, the projections bearing against fibers passing through the holes;
- placing a binder on the fibers on the first side of the pierced sheet in the selected regions;
- and
- fusing the binder to the carrier sheet to anchor bases of the loops.
2 more elements
A method of making a loop fastener product, the method comprising
- placing a layer of fibers against a first side of a carrier sheet of film, the layer of fibers having an overall density of less than about 5 ounces per square yard and the film having an overall thickness of less than about 0.005 inch;
- needling fibers of the layer through the film by piercing the film with forked needles that drag portions of the fibers through holes formed in the film during needling, leaving loops of the fibers extending from the holes on a second side of the carrier sheet, wherein the carrier sheet forms projections extending out of a general plane of the carrier sheet at the holes, the projections bearing against fibers passing through the holes;
- fusing the fibers to the film to anchor bases of the loops;
- and
- embossing the second side of the carrier sheet to impart a desired pattern to the loop surface.
2 more elements
A method of making a loop fastener product, the method comprising
- placing a layer of fibers against a first side of a carrier sheet of film, the layer of fibers having an overall density of less than about 5 ounces per square yard and the film having an overall thickness of less than about 0.005 inch;
- needling fibers of the layer through the film by piercing the film with forked needles that drag portions of the fibers through holes formed in the film during needling, leaving loops of the fibers extending from the holes on a second side of the carrier sheet, wherein the carrier sheet forms projections extending out of a general plane of the carrier sheet at the holes, the projections bearing against fibers passing through the holes;
- and
- fusing the fibers to the film to anchor bases of the loops;
- wherein the loop fastener product has an overall weight of less than about 15 ounces per square yard (500 grams per square meter).
2 more elements
Dependencies are inferred from the claim text.