Abstract:
A method for fabricating a plastic spacer/riser to increase useable height of a reclosable fastening system, such as 3M™ Dual Lock™ or Velcro® hook and loop products. The spacer/riser is adapted to be held in place on an external substrate with hot-melt glue, sonic welds, pressure-sensitive adhesives, acrylic foam tape, or screws.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present patent application is a division of U.S. patent application Ser. No. 12/712,016 filed Feb. 24, 2010, now U.S. Pat. No. 7,909,393 issued Mar. 22, 2011, which in turn is a continuation of U.S. patent application Ser. No. 11/681,060 filed Mar. 1, 2007, now U.S. Pat. No. 7,695,057 issued Apr. 13, 2010 which in turn is a continuation-in-part of and claims priority from U.S. patent application Ser. No. 11/162,499 filed Sep. 13, 2005, now U.S. Pat. No. 7,390,057 issued Jun. 24, 2008, which in turn is a continuation-in-part and claims priority from U.S. Provisional Application Ser. No. 60/609,427 filed Sep. 13, 2004, the entire contents of which applications are incorporated herein by reference thereto. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not applicable. 
     REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC 
     Not applicable. 
     BACKGROUND OF THE INVENTION 
     The present invention relates generally to a reclosable fastener riser/spacer device, and methods of constructing and using same. 
     More particularly, the present invention relates to an extruded plastic spacer/riser device to increase the useable height of reclosable fastening systems, such as, for example, 3M™ Dual Lock™ or Velcro® hook and loop products, and methods of constructing and utilizing same. 
     The term “reclosable fastener” as used herein means 3M™ Dual Lock™ fasteners, Velcro® hook and loop fasteners, and any other fastener that is selectively reclosable. 
     Typically, reclosable fastening systems, such as, for example, 3M™ Dual Lock™ or Velcro® hook and loop products, are limited in their overall height or thickness in application. 
     Many times there is a need to increase the overall height or thickness of these fasteners. 
     For example, when using a reclosable fastener for fastening together the headliner of an automobile and the sheet metal portion roof of the automobile, oftentimes there is a space or gap between the parts of the reclosable fasteners which might necessitate the pushing in of the headliner, resulting in an uneven look with creases and folds and the like. 
     The present invention provides a device to increase the overall height, allowing more versatility in the use of reclosable fasteners in many different applications. 
     It is a desideratum of the present invention to avoid the animadversions of conventional reclosable fastening systems which are limited in their overall height or thickness in application. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention provides a riser/spacer device for use with a reclosable fastener, comprising, in combination: a riser/spacer device a having a first predetermined overall height, and first and second predetermined portions; a reclosable fastener having a second predetermined overall height, and selectively closable and releasable first and second mating portions; said first mating portion of said reclosable fastener being secured to said first predetermined portion of said riser/spacer device; said first predetermined overall height of said riser/spacer device plus and said second predetermined overall height of said reclosable fastener being determined by a gap to be filled between first and second external substrates; said second predetermined portion of said riser/spacer device being connected, directly or indirectly, to said first external substrate; and said second mating portion of said reclosable fastener being connected, directly or indirectly, to said second external substrate. 
     The present invention also provides a method of fabricating a riser/spacer device, comprising the steps of: softening plastic in an extruder as said plastic is forced though said extruder by an extruder screw toward a die; shaping said softened plastic in said die; holding the shape of said plastic with shaping tooling and guides as said softened shaped plastic exits said die in a continuous length until said softened shaped plastic is cooled and set to a required shape and dimensions of said riser/spacer device; and maintaining the size of the plastic riser/spacer device by a ratio between the amount of plastic being forced through said die and the speed of a haul off apparatus pulling the plastic riser/spacer device away from said die and through shaping tooling and guides. 
     The invention also provides a riser/spacer device which includes first and second mating channel members which are designed and dimensioned to be slidably assembled and disassembled together; and said first and second mating channel members are disposed between said first mating portion of said reclosable fastener and said first external substrate. 
     The present invention further provides an extruded spacer/riser device as described hereinabove to increase the useable height of reclosable fastening systems, such as, for example, 3M™ Dual Lock™ or Velcro® hook and loop products. 
     It is a primary object of the present invention to provide a reclosable fastener riser/spacer product as described hereinabove, wherein such riser/spacer product may be fabricated by extrusion out of materials such as ABS, polypropylene, polyethylene, or any suitable material. 
     Another object of the present invention is to provide such a riser/spacer device as described hereinabove, which allows reclosable fastening systems to have more versatility in applications. 
     Another object of the present invention is to provide such a riser/spacer device as described hereinabove, wherein the riser/spacer device is designed to be held in place on a substrate with hot-melt glue, sonic welding, pressure sensitive adhesive, acrylic foam tape, screws, or other securement means. 
     The foregoing objects, advantages and features of the present invention will become apparent to those persons skilled in this particular area of technology and to other persons after having been exposed to the following detailed description of the present invention and when read in conjunction with the accompanying patent drawings. 
     For a better understanding of the present invention, and to show more clearly how it may be carried into effect, reference will now be made, by way of example, to the accompanying drawings, which show some preferred embodiments of the present invention. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         FIG. 1  illustrates a top plan view of a spacer/riser device in accordance with a first embodiment of the invention. 
         FIG. 2  shows a front elevational view of the  FIG. 1  device. 
         FIG. 3  shows a side elevational view of the  FIG. 1  device. 
         FIG. 4  illustrates a bottom view of the  FIG. 1  device. 
         FIG. 5  is a view similar to  FIG. 2  but showing the internal structure of the spacer in phantom line. 
         FIG. 6  is a view similar to  FIG. 3  but showing the internal structure of the spacer in phantom line. 
         FIG. 7  is an isometric drawing showing the device having affixed thereon one portion of a 3M™ Dual Lock™ reclosable fastener. 
         FIG. 8  shows a side elevational view, partly in section, of the riser/spacer device of the present invention as used with a particular reclosable fastener system. 
         FIG. 9  illustrates a perspective view of a second embodiment of the invention. 
         FIG. 10  shows an end view of the  FIG. 9  embodiment. 
         FIG. 11  illustrates a third embodiment. 
         FIG. 12  shows a device for mating with the  FIG. 11  embodiment. 
         FIG. 13  depicts a bottom view of the  FIG. 12  device. 
         FIG. 14  is a front view of the  FIG. 12  device inverted. 
         FIG. 15  is view of the unassembled dual-lock fastener of  FIGS. 12-14 . 
         FIG. 16  shows the  FIG. 15  fastener on acrylic foam tape. 
         FIG. 17  is a side view of  FIG. 14 . 
         FIG. 18  shows a top view of the unassembled acrylic foam tape of the  FIG. 11  device. 
         FIG. 19  is a front view of  FIG. 18 . 
         FIG. 20  is a partial perspective view of a fourth embodiment of the invention. 
         FIG. 21  is front view of  FIG. 20 . 
         FIG. 22  is a front view of a first channel portion of  FIG. 20 . 
         FIG. 23  is a front view of second channel portion which mates with  FIG. 22  device. 
         FIG. 24  is a partial perspective view of a fifth embodiment of the invention. 
         FIG. 25  is front view of  FIG. 24 . 
         FIG. 26  is a front view of a first channel portion of  FIG. 24 . 
         FIG. 27  is a front view of second channel portion which mates with  FIG. 26  device. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Similar components in the various embodiments are designated by the same reference numbers, unless indicated otherwise. 
     The invention provides a riser/spacer device  18  for use with a reclosable fastener  17 , wherein: the riser/spacer device has a first predetermined overall height, and first and second predetermined portions  19  and  26 ; the reclosable fastener  17  has a second predetermined overall height, and selectively closable and releasable first and second mating portions  16  and  22 ; said first mating portion  16  of said reclosable fastener  17  being secured to said first predetermined portion  19  of said riser/spacer device  18 ; said first predetermined overall height of said riser/spacer device  18  plus and said second predetermined overall height of said reclosable fastener  17  being determined by a gap to be filled between first and second external substrates  20  and  23 ; said second predetermined portion  26  of said riser/spacer device  18  being connected to said first external substrate  20 ; and said second mating portion  22  of said reclosable fastener  17  being connected to said second external substrate  23 . 
     With reference to  FIGS. 1-8 , there is illustrated a first embodiment of the present invention in the form of an unitarily-molded riser/spacer device  18  having a main spacer retainer member  10  and a spacer  15 . 
     Preferably, but not necessarily, the main spacer retainer member  10  is provided around its outer periphery  11  with a series of apertures  12 . 
     The main spacer retainer member  10  is provided with a predetermined portion or base member  26  having a lower surface  27 , as best shown in  FIG. 8 . 
     The main spacer retainer member  10  surrounds one or more spacer members  15 , the height of which is dependent upon the increase in height or gap to be filled between external substrates  20  and  23 . 
     Preferably, but not necessarily, the device  18  is injection molded from materials such as ABS, polypropylene, polyethylene, or other plastics. 
     With reference to  FIG. 7 , there is shown the device  18  having affixed at a predetermined portion or top surface  19  thereof a first mating portion  16  of a reclosable fastener  17 , such as a 3M™ Dual Lock™ reclosable fastener. 
     With reference to  FIG. 8 , there is shown the device  18  having the lower surface portion  27  of its base number  26  secured to a first external substrate  20 , such as the sheet metal roof of an automobile, by hot-melt glue, sonic welding, pressure-sensitive adhesive, or other securement means  21 . 
     A second portion  22  of the reclosable fastener  17 , such as a 3M™ Dual Lock™ reclosable fastener, is secured to a second external substrate  23 , such as, for example, the headliner of an automobile by hot-melt glue, sonic welding, pressure-sensitive adhesive, or other securement means  28 . 
     With reference to  FIGS. 7 and 8 , the purpose of the apertures  12  in the main spacer retaining member  10  is to permit hot-melt glue or other adhesive to move therethrough, or screws to pass therethrough, when securing member  10  to an external substrate  20 . 
     With reference to  FIG. 8 , the 3M™ Dual Lock™ reclosable fastener  17  will operate in the normal fashion with the mushroom heads  25  on the rigid plastic stems  24  releasably interlocked. The 3M™ Dual Lock™ reclosable fasteners  17  are self-mating, that is the fasteners  17  simply reattach to themselves. When pressed together, thousands of mushroom heads  25  interlock with one another creating an audible snap that announces that the fastener portions  16  and  22  are interlocked. 
       FIGS. 9 and 10  a riser/spacer device  40  in accordance with a second embodiment of the invention. 
     The riser/spacer device  40  is made by an extrusion process as described hereinbelow. 
     In the extrusion process in accordance with the present invention, the plastic from which the device  40  is made has to be softened so it can be shaped. This can be done by any suitable means, such as, for example, by applying heat. 
     In accordance with the invention, this softening of the plastic takes place in an extruder as the plastic is forced toward and through a die by an extruder screw. The shape is imparted to the plastic by the die. 
     Once the plastic exits the die in a continuous length, it is held or maintained in shape with shaping tooling and guides until the plastic material can be cooled and set to the required shape. 
     The size of the plastic part is maintained by a ratio between the amount of plastic being forced through the die and the speed of an haul off apparatus which pulls the part away from the die and through the shaping tooling. 
     After the part shape has been set, any number of process steps can be done to the part while it is still in a continuous length and before it passes through the haul off apparatus. In the case of the riser/spacer device  40 , these process steps may preferably, but not necessarily, include applying promoter, applying a portion  41  (similar to portion  16  described above) of a reclosable fastener  17 , and applying a part identification. 
     Once the part is beyond the haul off apparatus, it may be cut to the required length, yielding the finished part. 
     With reference to  FIGS. 9 and 10 , the riser/spacer device  40  includes a reclosable fastener somewhat similar to the reclosable fastener  17  described above in connection with  FIGS. 7 and 8 . The reclosable fastener  17  has a predetermined overall height “a” (as shown in  FIG. 8 ), and a selectively closable and releasable first and second mating portions. 
     Also, as shown in  FIG. 8 , the predetermined overall height of the riser/spacer device plus and the predetermined overall height “a” of the reclosable fastener is determined by a gap “b” to be filled between first and second external substrates  20  and  23 . 
     As shown in  FIG. 8 , a mating portion  22  of the reclosable fastener  17  is secured to an external substrate  23 . 
     The mating portion  41  ( FIGS. 9 and 10 ) is similar to the mating portion  16 . 
       FIGS. 11-19  illustrate a third embodiment  50  having first and second riser/spacer devices  51  and  52 , and a reclosable fastener  17 .  FIG. 11  show mating portion  16  of fastener  17  mounted on spacer  51 , which in turn is mounted on acrylic foam tape member  53 . 
       FIG. 12  shows the device for mating with the  FIG. 11  device.  FIG. 12  shows mating portion  22  of fastener  17  secured to spacer  52 , which in turn is secured to acrylic foam tape member  54 . 
       FIG. 13  depicts a bottom view of the  FIG. 12  device. 
       FIG. 14  is a front view of the  FIG. 12  device inverted. 
       FIG. 15  is view of the unassembled dual-lock fastener of  FIGS. 12-14 . 
       FIG. 16  shows the  FIG. 15  fastener on acrylic foam tape. 
       FIG. 17  is a side view of  FIG. 14 . 
       FIG. 18  shows a top view of the unassembled acrylic foam tape of the  FIG. 11  device. 
       FIG. 19  is a front view of  FIG. 18 . 
       FIG. 20  is a partial perspective view of a fourth embodiment  60  of the invention. 
       FIG. 21  is front view of  FIG. 20 . 
       FIG. 22  is a front view of a first channel portion  61  of  FIG. 20 . 
       FIG. 23  is a front view of second channel portion  62  which mates with the  FIG. 22  device. 
       FIG. 24  is a partial perspective view of a fifth embodiment  70  of the invention. 
       FIG. 25  is front view of  FIG. 24 . 
       FIG. 26  is a front view of a first channel portion  71  of  FIG. 24 . 
       FIG. 27  is a front view of second channel portion  72  which mates with the  FIG. 26  device. 
     With reference to the fourth and fifth embodiments  60  and  70 , respectively, it should be noted that the device includes first and second mating channel members which are designed and dimensioned to be slidably assembled and disassembled together; and said first and second mating channel members are disposed between said first mating portion of said reclosable fastener and said first external substrate. 
     The invention provides a method of fabricating a riser/spacer device, comprising the steps of: softening plastic in an extruder as said plastic is forced though said extruder by an extruder screw toward a die; shaping said softened plastic in said die; holding the shape of said plastic with shaping tooling and guides as said softened shaped plastic exits said die in a continuous length until said softened shaped plastic is cooled and set to a required shape and dimensions of said riser/spacer device; and maintaining the size of the plastic riser/spacer device by a ratio between the amount of plastic being forced through said die and the speed of a haul off apparatus pulling the plastic riser/spacer device away from said die and through shaping tooling and guides. 
     The invention also provides a method as described above, including the steps of: after said required shape of said plastic riser/spacer device has been set and while said plastic riser/spacer device is still in said continuous length and before said plastic riser/spacer device passes through said haul off apparatus, applying promoter to at least a portion of the riser/spacer device, and a part identification for said riser/spacer device. 
     The invention also provides a method as described above, including the step of: after said plastic riser/spacer device is beyond said haul off apparatus, cutting said plastic riser/spacer device to its required length yielding a finished riser/spacer device. 
     The invention also provides a method as described above, wherein: at least one predetermined portion of said riser/spacer device is provided with extruded texture, grooves or uneven portions to facilitate securement to an external substrate by at least one of hot-melt glue, sonic welding, pressure-sensitive adhesive, acrylic foam tape, and other securement means. 
     The invention also provides a method as described above for fabricating a riser/spacer device for use with a reclosable fastener, comprising, in combination: a riser/spacer device a having a first predetermined overall height, and first and second predetermined portions; said riser/spacer device having a rectangular structure including at least one hollow portion which extends the complete length of said rectangular structure parallel to the central elongated longitudinal axis of said rectangular structure; a reclosable fastener having a second predetermined overall height, and selectively closable and releasable first and second mating portions; said reclosable fastener comprises strips of flexible plastic covered with interlocking heads which fasten securely when pressed together; said first mating portion of said reclosable fastener being secured to said first predetermined portion of said riser/spacer device; said first predetermined overall height of said riser/spacer device plus and said second predetermined overall height of said reclosable fastener being determined by a gap to be filled between first and second substrates; said second predetermined portion of said riser/spacer device being connected to said first substrate; and said second mating portion of said reclosable fastener being connected to said second substrate. 
     The invention also provides a method as described above, wherein said first predetermined overall height of said riser/spacer device is set and shaped by the extrusion process in forming and producing said riser/spacer device. 
     The invention also provides a method as described above, wherein said first mating portion of said reclosable fastener is secured to a first predetermined portion of said riser/spacer device by at least one of hot-melt glue, sonic welding, pressure-sensitive adhesive, and acrylic foam tape. 
     The invention also provides a method as described above, wherein said second predetermined portion of said riser/spacer device is connected to said first substrate by at least one of hot-melt glue, sonic welding, pressure-sensitive adhesive, and acrylic foam tape. 
     The invention also provides a method as described above, wherein said second mating portion of said reclosable fastener is secured to said second substrate by at least one of hot-melt glue, sonic welding, pressure-sensitive adhesive, and acrylic foam tape. 
     The invention also provides a method as described above, wherein said second predetermined portion of said riser/spacer device is provided with extruded texture, grooves or uneven portions to facilitate said connection to said first substrate by at least one of hot-melt glue, sonic welding, pressure-sensitive adhesive, and acrylic foam tape. 
     The invention also provides a method as described above for fabricating a riser/spacer device for use with a reclosable fastener, comprising, in combination: a reclosable fastener having a predetermined overall height, and selectively closable and releasable first and second mating portions; said reclosable fastener comprises strips of flexible plastic covered with interlocking heads which fasten securely when pressed together; a first rigid, one-piece, non-deformable, non-flexible riser/spacer member having a rectangular parallelepiped shape with a pair of parallel rectangular tubular hollow portions extending therethrough; said first mating portion of said reclosable fastener being secured to a first major planar surface of said first rigid, one-piece, non-deformable, non-flexible riser/spacer member; a first acrylic foam tape member secured to a second major planar surface of said first rigid, one-piece, non-deformable, non-flexible riser/spacer member; said second major planar surface is parallel to and opposite said first major planar surface; said first acrylic foam tape member extends beyond said first rigid, one-piece, non-deformable, non-flexible riser/spacer member to provide wing portions on both ends of said first rigid, one-piece, non-deformable, non-flexible riser/spacer member; a second rigid, one-piece, non-deformable, non-flexible riser/spacer member having a rectangular parallelepiped shape with a pair of parallel rectangular tubular hollow portions extending therethrough; said second mating portion of said reclosable fastener being secured to a first major planar surface of said second rigid, one-piece, non-deformable, non-flexible riser/spacer member; a second acrylic foam tape member secured to a second major planar surface of said second rigid, one-piece, non-deformable, non-flexible riser/spacer member; said second major planar surface of said second riser/spacer member is parallel to and opposite said first major planar surface of said second riser/spacer member; when said strips of flexible plastic covered with interlocking heads are fastened securely pressed together, the overall height of all of the above-mentioned components is determined by a gap to be filled between first and second substrates; said first acrylic foam tape member is secured to said first substrate; and said second acrylic foam tape member is secured to said second substrate. 
     The invention also provides a method as described above for fabricating a riser/spacer device for use with a reclosable fastener, comprising, in combination: a riser/spacer device a having a first predetermined overall height, and first and second predetermined portions; said riser/spacer device having a rectangular structure including at least one hollow portion which extends the complete length of said rectangular structure parallel to the central elongated longitudinal axis of said rectangular structure; a reclosable fastener having a second predetermined overall height, and selectively closable and releasable first and second mating portions; said reclosable fastener comprises strips of flexible plastic covered with interlocking heads which fasten securely when pressed together; said first mating portion of said reclosable fastener being secured to said first predetermined portion of said riser/spacer device; said first predetermined overall height of said riser/spacer device plus and said second predetermined overall height of said reclosable fastener being determined by a gap to be filled between first and second substrates; said second predetermined portion of said riser/spacer device being connected to said first substrate; and said second mating portion of said reclosable fastener being connected to said second substrate. 
     While the present invention has been described hereinabove with respect to several preferred embodiments for illustrative purposes only, it should be understood that the present invention encompasses and embraces all modifications, variations, and changes in the basic inventive concept. 
     Also, the variations and modifications are intended to be embraced within the scope of the present invention and the patent claims set forth hereinbelow.