# US 8,784,722 B2 · Method and apparatus for producing hook fasteners > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,784,722 B2 - Document ID: US8784722B2 - Status: Granted - Kind: B2 - Application number: 12/690,700 - Filed: 2010-01-20 - Published: 2010-07-22 - Granted: 2014-07-22 - Earliest claimed: 2009-01-20 - Applicants: Gerald Rocha - Inventors: Gerald Rocha - Web page: https://patentgrep.com/patent/US8784722B2 ## CPC - 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)} - B29C 59/04: using rollers or endless belts - A44B 18/0046: {Fasteners made integrally of plastics} - B29C 59/025: {Fibrous surfaces with piles or similar fibres substantially perpendicular to the surface} - B29C 59/046: {for layered or coated substantially flat surfaces} - B29L 2031/729: {Hook and loop-type fasteners} - Y10T 24/2792: having mounting surface and filaments constructed from common piece of material - A44B: BUTTONS, PINS, BUCKLES, SLIDE FASTENERS, OR THE LIKE (fastenings specially adapted for footwear A43C) - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract Apparatus and process are described for forming projections on a substrate for use as hook-type fasteners in touch fastening systems, wherein vibration energy may be used to soften a substrate which may be positioned between a mold and a source of vibration. The mold may include a plurality of cavities into which the softened substrate may be forced to form the projections. The substrate may comprise a film, sheet, web, composite, laminate, etc. and be useful as an attachment strip for temporary or permanent fastening. The source of vibration may be an ultrasonic horn. The process to form such projections may be operated in a continuous, semi-continuous or intermittent manner. ## Claims ### Claim 1 A process for forming projections suitable for use in a touch fastener on a substrate comprising: providing a first device having an outer surface; providing a substrate material having a first surface; providing a second device as a source of vibration energy; wherein said first device and/or said second device contains a plurality of cavities, at least some of said cavities having a shape to produce a projection suitable for use in a touch fastener; positioning said substrate material between said first device and said second device; applying power to said second device to locally soften said substrate material such that a portion of said softened substrate material is forced into said cavities to form projections suitable for use in a touch fastener on a portion of said first surface of said substrate material and a portion of said substrate material serves as a touch fastener carrier for said projections. ### Claim 2 (depends on 1) The process of claim 1 wherein at least a portion of said first device and/or said second device includes a wavy surface and further comprising forming at least a portion of said substrate material into a creped area. ### Claim 3 (depends on 1) The process of claim 1 wherein applying power to said second device comprises applying intermittent power to said second device. ### Claim 4 (depends on 1) The process of claim 1 wherein providing a substrate material comprises providing a film, sheet, web, composite, laminate, foam, fabric, non-woven, fiber-reinforced, thermoplastic and/or thermoset material. ### Claim 5 (depends on 1) The process of claim 1 wherein providing a first device comprises providing a first rotating roll. ### Claim 6 (depends on 5) The process of claim 5 wherein providing a second device comprises providing a second rotating roll. ### Claim 7 (depends on 1) The process of claim 1 wherein providing a first device comprises providing a rotating roll and wherein providing a second device comprises providing a stationary second device. ### Claim 8 (depends on 1) The process of claim 1 wherein providing a second device as a source of vibration energy comprises providing a second device as a source of mechanical or electromechanical or acoustical vibration energy. ### Claim 9 (depends on 1) The process of claim 1 wherein providing a second device comprises providing an ultrasonic horn. ### Claim 10 (depends on 1) The process of claim 1 wherein providing a substrate material comprises providing a first layer and a second layer, with said first layer having one or more openings which expose a surface of a second layer, and wherein forming projections comprises forming projections on said surface of said second layer. ### Claim 11 (depends on 1) The process of claim 1 wherein providing a substrate material comprises providing a laminate comprising continuous and/or intermittent layers of different materials. ### Claim 12 (depends on 1) The process of claim 1 further comprising removing said projections from said cavities and post-forming said projections into a desired shape. ### Claim 13 (depends on 12) The process of claim 12 wherein post-forming said projections comprises applying vibration energy to said projections. ### Claim 14 (depends on 12) The process of claim 12 wherein post-forming said projections comprises post-forming said projections to include mushroom-shaped heads, multi-lobed heads, multi-limbed heads, grappling hook heads or combinations thereof. ### Claim 15 (depends on 1) The process of claim 1 further comprising engaging said projections with a second substrate material having one or more of loop elements, complementary shaped projections or other mating features to fasten said substrate material to said second substrate material. ### Claim 16 (depends on 1) The process of claim 1 further comprising applying vibration energy to aid in removing said projections from said cavities. ### Claim 17 (depends on 1) The process of claim 1 further comprising passing a second substrate material between said substrate material and said first device or said second device and exposing said second substrate material to said vibration energy thereby causing said second substrate material to adhere to said substrate material. ### Claim 18 (depends on 17) The process of claim 17 further comprising forming at least a portion of said projections with said second substrate material. ### Claim 19 (depends on 1) The process of claim 1 wherein providing a substrate material comprises providing a portion of a diaper. ### Claim 20 (depends on 2) The process of claim 2 wherein providing a substrate material comprises providing a portion of a diaper and wherein forming at least a portion of said substrate material into said creped area comprises forming at least a portion of said substrate material into said creped area adjacent a region containing said projections. ### Claim 21 (depends on 1) The process of claim 1 further comprising forming apertures in said substrate. ### Claim 22 A process for forming projections suitable for use in a touch fastener on a substrate comprising: providing a substrate material having a first surface; providing a device as a source of vibration energy, said device having a surface containing a plurality of cavities, said cavities arranged along at least a portion of said surface, at least some of said cavities having a shape to produce a projection suitable for use in a touch fastener; pressing said device against said first surface of said substrate material; applying power to said device to locally soften said substrate material such that a portion of said softened substrate material is forced into said cavities in said surface of said device to form projections suitable for use in a touch fastener on said first surface of said substrate material, said projections generally conforming to said shape of said cavities, a portion of said substrate serves as a touch fastener carrier for said projections. ### Claim 23 (depends on 22) The process of claim 22 further comprising manually or automatically pressing said device against said first surface of said substrate material. ### Claim 24 (depends on 22) The process of claim 22 further comprising removing said projections from said cavities and post-forming said projections into a desired shape. ### Claim 25 (depends on 24) The process of claim 24 wherein post-forming said projections comprises applying vibration energy to said projections. ### Claim 26 (depends on 24) The process of claim 24 wherein post-forming said projections comprises post-forming said projections to include mushroom-shaped heads, multi-lobed heads, multi-limbed heads, grappling hook heads or combinations thereof. ### Claim 27 (depends on 22) The process of claim 22 further comprising passing a second substrate material between said substrate material and said device and exposing said second substrate material to said vibration energy thereby causing said second substrate material to adhere to said substrate material. ### Claim 28 (depends on 22) The process of claim 22 wherein providing a substrate comprises providing an automotive trim panel. ### Claim 29 (depends on 11) The process of claim 11 wherein providing a laminate of different materials comprises providing a laminate of different materials including one or more of foam, fiber-reinforced plastic, oriented thermoplastic or thermosetting materials. ### Claim 30 (depends on 1) The process of claim 1 wherein said cavities are shaped to form projections which are shaped as one or more of hooks, mushrooms, straight pins, angled pins, tapered pins, curved pins, grappling hook, multi-limbed, cross-shaped, Y-shaped and multi-lobed, each having cross-sections which are round, oval, square, rectangular, trapezoidal, solid, hollow and combinations thereof. ### Claim 31 (depends on 22) The process of claim 22 wherein said cavities are shaped to form projections which are shaped as one or more of hooks, mushrooms, straight pins, angled pins, tapered pins, curved pins, grappling hook, multi-limbed, cross-shaped, Y-shaped and multi-lobed, each having cross-sections which are round, oval, square, rectangular, trapezoidal, solid, hollow and combinations thereof. ### Claim 32 (depends on 22) The process of claim 22 wherein providing a substrate material comprises providing a film, sheet, web, composite, laminate, foam, fabric, non-woven, fiber-reinforced, thermoplastic and/or thermoset material. ### Claim 33 (depends on 17) The process of claim 17 wherein passing a second substrate material between said substrate material and said first device or said second device comprises passing a laminate between said substrate material and said first device or said second device, wherein said laminate comprises a continuous and/or intermittent layers of different materials. ### Claim 34 (depends on 33) The process of claim 33 wherein passing a laminate between said substrate material and said first device or said second device comprises providing a laminate of different materials including one or more of foam, fiber-reinforced plastic, oriented thermoplastic or thermosetting materials. ### Claim 35 (depends on 1) The process of claim 1 further comprising passing a second material between said substrate material and said first device or said second device, wherein said second material comprises paper or metal. ### Claim 36 (depends on 22) The process of claim 22 further comprising passing a second material between said substrate material and said device, wherein said second material comprises paper or metal. ### Claim 37 (depends on 22) The process of claim 22 wherein providing a substrate material comprises providing a laminate comprising continuous and/or intermittent layers of different materials. ### Claim 38 (depends on 37) The process of claim 37 wherein providing a laminate of different materials comprises providing a laminate of different materials including one or more of foam, fiber-reinforced plastic, oriented thermoplastic or thermosetting materials. ### Claim 39 (depends on 27) The process of claim 27 wherein passing a second substrate material between said substrate material and said device comprises passing a laminate between said substrate material and said first device or said second device, wherein said laminate comprises a continuous and/or intermittent layers of different materials. ### Claim 40 (depends on 39) The process of claim 39 wherein passing a laminate between said substrate material and said device comprises providing a laminate of different materials including one or more of foam, fiber-reinforced plastic, oriented thermoplastic or thermosetting materials. ### Claim 41 (depends on 1) The process of claim 1 further comprising applying power to said second device to form projections suitable for use in a touch fastener on a portion of a second surface of said substrate opposite said first surface of said substrate. ### Claim 42 (depends on 22) The process of claim 22 further comprising applying power to said device to form projections suitable for use in a touch fastener on a portion of a second surface of said substrate opposite said first surface of said substrate.