Patent ID: 6855220
Filing Date: 2005-02-15
Classification: A44B,A61F,B32B,D04B,D10B,Y10T

Abstract:
1. A method for forming a composite sheet material adapted to be cut into smaller pieces to form a female portion of a tear away fastener system for a diaper, said method comprising the steps of: providing a substrate layer having a first face and a second face projecting away from said second face; providing a plurality of yarns of textured multi-filament construction to positions in spaced opposing relation to said second face, wherein said yarns includes plurality of discrete filaments; blooming said plurality of yarns by application of heat so as to at least partially spread said filaments apart; pulling segments of said plurality of yarns through said substrate layer from the positions in spaced opposing relation to said second face using reciprocating needles that hookingly engage said plurality of yarns such that the segments pulled through the substrate layer form a plurality of looped elements projecting away from said first face and such that segments of said plurality of yarns between said looped elements project away from said second face of said substrate layer, wherein upon hooking engagement between said reciprocating needles and said plurality of yarns said reciprocating needles project across said substrate layer from positions opposing said first face and wherein said plurality of yarns are manipulated in a predefined manner by moveable yarn guide elements such that during a given cycle of penetration and withdrawal of said reciprocating needles across the substrate layer, at least a portion of said plurality of yarns are shifted away from hooking engagement with the reciprocating needles that engaged said at least a portion of said plurality of yarns during an immediately preceding cycle of penetration and withdrawal and such that during said given cycle of penetration and withdrawal at least a portion of the reciprocating needles that engaged said at least a portion of said plurality of yarns during said immediately preceding cycle do not do not pull any segment of yarn through the substrate layer upon withdrawal from the substrate layer, such that a predefined pattern of needle punctures containing yarn segments defining base segments of looped elements is formed across the substrate layer in combination with empty needle punctures disposed in a predefined pattern between at least a portion of the looped elements, whereby the number of looped elements is less than the total number of needle punctures; and anchoring said yarns in position within said substrate layer by means of a substantially resilient polymeric material defining a backing layer disposed at least partially around segments of said plurality of yarns projecting away from said second face of said substrate layer.