Abstract:
A fastener element with a sheet-form base and an array of wedge-shaped engageable elements molded integrally with a surface of the sheet-form base. The wedge-shaped elements each have a steep side and a gradually rising side, and are arranged with their steep sides all directed in a common sense, such that the array can engage a similar array of oppositely-directed wedge-shaped elements to resist shear motion. The distal edges of the wedges are curved in top view.

Description:
TECHNICAL FIELD  
       [0001]     This invention relates to fastener products such as those having an array of projections arranged to resist shear displacement across the surface of the fastener product.  
       BACKGROUNDS  
       [0002]     Some fasteners, for example, hook and loop fasteners, include fastener components with engageable elements constructed to engage elements of corresponding fastener components. In the case of self-engaging fasteners, the fastener elements of the two fastener components are similar or the same, and the two fastener components may be regions of a single sheet.  
         [0003]     There is a need in certain applications for fasteners that, when engaged, provide high shear strength properties in a desired direction. Some applications also require low cost fasteners offering good resistance to disengagement and in-place adjustability.  
         [0004]     There is also a need to be able to consistently and efficiently produce fastener components having differing functional characteristics, using techniques that require limited changeover in basic tooling, yet allow for adjustments to produce the desired fastener characteristics.  
       SUMMARY  
       [0005]     According to one aspect of the invention, a self-engageable fastener component includes a sheet-form base, and an array of wedge-shaped, engageable elements extending integrally from at least one side of the sheet-form base. The engageable elements each have an engageable side, and a non-engageable side conterminous at an upper edge of the element. The upper edge of each engageable element defines a curve in top view, and the engageable sides of a majority of the elements are oriented in a common direction.  
         [0006]     In some embodiments, the engageable elements are arranged in at least one row along the sheet-form base, the row extending toward the single edge. For some applications, the elements are arranged in an array of multiple rows and columns. In preferred embodiments, the elements are arranged in multiple rows, with elements of adjacent rows offset from one another along their respective rows. The elements of adjacent rows are offset, for example, by about one-half a nominal spacing between adjacent elements within a row.  
         [0007]     In some implementations, the curve defined by the upper edge in top view is substantially circular with a constant radius of curvature. In preferred implementations, the constant radius of curvature is from about 0.25 to 2.5 centimeters.  
         [0008]     For some applications, the curve defined by the upper edge in top view is not circular, but is, for example, parabolic, ellipsoidal, hyperbolic, or a mixture of such curves.  
         [0009]     In preferred embodiments, a maximum elevation of the upper edge above the top surface of the sheet-form base is between about 0.025 and 6.3 millimeters, each engageable element has a width, measured along the sheet-form base perpendicular to said single edge, of between about 0.13 and 6.3 millimeters, each engageable element has a length, measured along the sheet-form base parallel to the edge, of between about 0.13 and 2.54 centimeters, and the non-engageable side of each fastener element rises from the sheet-form base at an angle of between about 5 and 45 degrees.  
         [0010]     In some instances, the engageable sides of the wedge-shaped elements overhang the sheet-form base, and the engageable side of each fastener element extends downward from the upper edge toward the sheet-form base at an undercut angle, measured in a midplane bisecting the fastener element and perpendicular to the sheet-form base, of between about 10 and 45 degrees.  
         [0011]     For some applications, the engageable elements extend outwardly from two opposite sides of the sheet-form base. In some instances, there are hook-shaped projections, and/or engageable loops proximate the wedge-shaped elements.  
         [0012]     In some implementations, the sheet-form base forms a tube, with the wedge-shaped elements extending from a curved surface of the tube. The curved surface can include an outer, or an inner surface of the tube. For some applications, the tube defines a longitudinal gap extending along its length between opposite edges of the sheet-form base. In some cases, the sheet-form base forms an elongated, U-shaped structure, and the wedge-shaped elements extend from an inside surface of the U-shaped structure, a majority of the engageable sides of the wedge-shaped elements directed away from an open edge of the U-shaped structure. In certain application, the wedge-shaped elements extend from an outside surface of the U-shaped structure.  
         [0013]     In some embodiments, the sheet-form base forms an elongated strap. In certain instances, the elongated strap includes only a single row of said wedge-shaped elements, all arranged with their engageable sides directed toward an end of the strap. For some applications, an aperture is defined adjacent one end of the strap, and the aperture sized to receive an opposite end of the strap therethrough. In preferred embodiments, the elongated strap includes an exposed retention edge along one side of the aperture, the retention edge is positioned to engage the engageable sides of the wedge-shaped elements with the opposite end of the strap pulled through the aperture, to resist removal of the strap from the aperture.  
         [0014]     For some applications, it is advantageous when the sheet-form base is secured to, and overlays a layer of resilient material, and the sheet-form base is flexible.  
         [0015]     In preferred embodiments, two fastener components, each as described above, are arranged with the engageable sides of their wedge-shaped elements overlapping one another to resist shear motion between the fastener components.  
         [0016]     According to another aspect of the invention, a method of making a fastener component includes providing a molding tool defining an array of cavities extending inwardly from an outer surface thereof. The moldable resin is transferred onto the outer surface of the molding tool, and the resin is pressed into the cavities of the molding tool, thus forming the engageable elements, while forming a base of resin on the surface of the molding tool, the base interconnecting the engageable elements. The cavities form engageable elements that are wedge-shaped, each wedge-shaped element including an engageable side, and a non-engageable side conterminous at an upper edge of the element. The upper edge of each engageable element defines a curve in top view, and the engageable sides of a majority of the elements are oriented toward a single edge of the sheet-form base.  
         [0017]     For some applications, the molding tool includes, for example, a rotatable mold roll positioned adjacent a counter-rotating pressure roll to define a pressure nip in which the moldable resin is pressed into the cavities to form the engageable elements. In some implementations, a sheet material is introduced into the nip with the moldable resin, and laminating the moldable resin to the sheet material under pressure in the nip. The sheet material can include, for example, a scrim material.  
         [0018]     In certain embodiments, the planar sheet material is formed into a tube, the engageable sides of a majority of the engageable elements being directed away from a common, open end of the tube.  
         [0019]     For some applications, the fastener component is in strap form, the method includes forming an aperture at one end of the fastener component, the aperture being sized to receive an opposite end of the fastener component. The fastener component includes an exposed retention edge along one side of the aperture, the retention edge being positioned to engage the engageable sides of the wedge-shaped elements with the opposite end of the strap pulled through the aperture, resisting removal of the strap from the aperture.  
         [0020]     According to another aspect of the invention, a seat bun includes a compliant material with a surface having a central region bounded on two opposite sides by elongated trenches, and a fastener component that includes a sheet-form base, and an array of wedge-shaped, engageable elements extending integrally from at least one side of the sheet-form base disposed within each trench. The engageable elements each have an engageable side, and a non-engageable side conterminous at an upper edge of the element. The upper edge of each engageable element defines a curve in top view, and the engageable sides of a majority of the elements are oriented in a common direction. The elements are arranged with the non-engageable sides of its wedge-shaped elements directed out of the trench. For some applications, the fastener components include elongated, U-shaped structures extending along each trench. In some instances, the fastener components comprise tubular structures embedded within each trench.  
         [0021]     The term “curve” as used herein is intended to include generally curved outlines that may encompass minor discontinuities or straight segments.  
         [0022]     The fastener components and fasteners disclosed herein can be particularly useful in applications requiring high shear strength. In addition to providing high shear strength, many of the fastener components and systems disclosed herein provide for ready disengagement and in-place fastener adjustability. Many embodiments can be molded in flexible form, with very low profile wedges, such that engaged sets of the fasteners occupy very little width between mating surfaces. The wedges can be arranged to allow engaged surfaces to be readily shifted for adjustment along rows of wedges, such as for adjusting the position of a picture frame fastened to a wall surface with such fasteners, for example, with the curved edges of the wedges of each row defining a series of detents for maintaining final engagement once shear load is reestablished between the wedges. The curvature of the edges helps to assist with adjustment of two mating arrays of wedges by allowing the apexes of the wedges to slide across one another without completely separating the mating fastener components, with the wedges overlapping.  
         [0023]     The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features and advantages of the invention will be apparent from the description and drawings and from the claims. 
     
    
     DESCRIPTION OF DRAWINGS  
       [0024]      FIG. 1  is a perspective view of a fastener component according to one embodiment.  
         [0025]      FIG. 1A  is an enlarged top view of a portion of the fastener component shown in  FIG. 1 .  
         [0026]      FIG. 1B  is an enlarged side view of a portion of the fastener component shown in  FIG. 1 .  
         [0027]      FIG. 1C  is a perspective view of a fastener component according to an alternative embodiment.  
         [0028]      FIG. 1D  is a top view of the fastener component of  FIG. 1C .  
         [0029]      FIG. 2  is a top view of the fastener component shown in  FIG. 1 .  
         [0030]      FIG. 2A  is a cross-sectional view of the fastener component shown in  FIG. 2 , taken along line  2 A- 2 A in  FIG. 2 .  
         [0031]      FIG. 2B  is an enlarged view of a portion of the fastener component shown in  FIG. 2A .  
         [0032]      FIG. 3  is a top view of the fastener component shown in  FIG. 2 , the fastener component oriented such that it is engaging a like fastener component, creating a fastener according to one embodiment.  
         [0033]      FIG. 3A  is a cross-sectional view of the fastener shown in  FIG. 3 , taken along  3 A- 3 A.  
         [0034]      FIGS. 3B-3C  are top views of a portion of the fastener system illustrated in  FIG. 3 .  
         [0035]      FIG. 4  is a diagrammatic view of a process for making the fastener component shown in  FIG. 1 .  
         [0036]      FIG. 4A  is a diagrammatic view of a process for making a fastener component shown in  FIG. 4B  or  4 C.  
         [0037]      FIG. 4B  is a laminated fastener component made by the process shown in  FIG. 4A .  
         [0038]      FIG. 4C  is a fastener component made by the process shown in  FIG. 4A  using a scrim web material.  
         [0039]      FIG. 4D  is a diagrammatic view of a process for making a fastener component with engageable elements on both sides of a sheet-form base.  
         [0040]      FIG. 5  is a diagrammatic view of an alternative process for making the fastener component shown in  FIG. 1 .  
         [0041]      FIG. 6  is a diagrammatic top view of a portion of flat tooling.  
         [0042]      FIG. 7  is a cross-sectional view of a tool roll being cut.  
         [0043]      FIG. 7A  is a side view of a dovetail cutter.  
         [0044]      FIG. 7B  is an end view of a dovetail cutter.  
         [0045]      FIGS. 8-9  are perspective views illustrating formation of a tubular fastener component with engaging elements on the inside.  
         [0046]      FIG. 9A  is a cross-sectional view of the fastener component shown in  FIG. 9  (after joining), taken along line  9 A- 9 A in  FIG. 9 .  
         [0047]      FIGS. 10-11  are perspective views illustrating formation of a tubular fastener component with engaging elements on the outside.  
         [0048]      FIG. 11A  is a cross-sectional view of the fastener component shown in  FIG. 11 , taken along line  11 A- 11 A in  FIG. 11 .  
         [0049]      FIG. 12  is a perspective view of a tubular fastener system employing the tubular fastener components shown in  FIGS. 9 and 11 .  
         [0050]      FIG. 13  is a perspective view of the tubular fastener component shown in  FIG. 9A  in a plastic body.  
         [0051]      FIG. 13A  is a side view of a fastener component according to an embodiment.  
         [0052]      FIG. 13B  is a side view of a fastener component according to another embodiment.  
         [0053]      FIG. 13C  is a cross-sectional view of a fastener system employing the fastener components of  FIGS. 13A and 13B .  
         [0054]      FIG. 14  is a perspective view of a mold insert illustrating the tubular fastener component of  FIG. 9  (after joining) on a protrusion.  
         [0055]      FIG. 14A  is a cross-sectional view of a tubular fastener component on a mold protrusion, a portion of the mold protrusion having a diameter larger than the nominal diameter of the fastener component, and the tubular fastener component including a region without engageable elements.  
         [0056]      FIG. 14B  is a cross-sectional view of a tubular fastener component on a mold protrusion, the fastener component including a seal about an inner surface of the tubular structure.  
         [0057]      FIG. 14C  is a cross-sectional view of a portion of a tubular fastener component showing overlapped edges that are tapered in thickness.  
         [0058]      FIGS. 15-16  are perspective views of alternative fastener components employing the fastener component shown in  FIG. 1 .  
         [0059]      FIG. 17  is a side view of a fastener component according to an embodiment.  
         [0060]      FIG. 18  is a side view of a fastener system according to an embodiment.  
         [0061]      FIG. 19  is a perspective view of a fastening system according to an embodiment.  
         [0062]      FIG. 20  is a perspective view of a fastener component according to an embodiment.  
         [0063]      FIG. 20A  is a perspective view of a fastening system according to an embodiment formed from the component of  FIG. 20 .  
         [0064]      FIG. 21  is an alternative fastening system.  
         [0065]      FIG. 22  is a fastener product.  
         [0066]      FIG. 23  is a partial cross-sectional view of a fastener product having a releasably retaining arm in a fastened position.  
         [0067]      FIG. 24  is a perspective view of a molding nip for producing the fastener product of  FIG. 26 .  
         [0068]      FIG. 25  shows area  25  of  FIG. 24 .  
         [0069]      FIG. 26  is a perspective view of a fastener product sheet, and a product that has been separated from the sheet.  
         [0070]      FIG. 27  is a plan view of the fastener product of  FIG. 26 .  
         [0071]      FIG. 28  is a cross-sectional view of a compliant material sandwiched between a tubular structure, and a base that includes engageable elements. 
     
    
     DETAILED DESCRIPTION  
       [0072]     Referring to  FIG. 1 , flexible fastener component  10  includes an array of arcuate engageable elements  12  integrally molded with and extending outwardly from one side of a solid sheet-form base  14 . The engageable elements  12  are arranged in scalloped rows R, and are preferably staggered, as shown. The engageable elements  12  each include an engageable side  18  and a non-engageable side  20  disposed opposite the engageable side. Preferably, the elements are substantially identical to each other, as shown.  
         [0073]     The engageable elements  12  may be formed by a process having a machine direction (MD) and a cross-machine direction (CD), in which case the engageable elements  12  may be arranged with rows R extending in the machine direction so that engageable sides  18  face uni-directionally in the cross-machine direction. Each engageable side  18  is defined by an upper edge  17  and by a lower edge  19  where the engageable element intersects the sheet-form base  14 . Both upper and lower edges  17 ,  19  define curves, for example, a circular curve as shown in  FIG. 1 , in the direction of the rows, for example, the machine direction. A circular curve is a curve that would sweep out a circle if it continued. Because the elements  12  are staggered, the apexes A 1 , A 2  of the arcuate engageable elements  12  in adjacent rows are offset from each other.  
         [0074]     In some embodiments, fastener component  10  is made of thermoplastic material. Suitable thermoplastic materials include polyethylenes, polypropylenes, polyamides, PVC, and polyesters. In other embodiments, especially when high chemical resistance and/or high temperature stability is required, fastener component  10  is made of a thermoset material. Suitable thermoset materials include natural rubbers, synthetic rubbers and rigid or flexible polyurethanes.  
         [0075]     In some embodiments, the upper and/or lower edge(s)  17 , 19  may define a circular curve with a constant radius of curvature. To illustrate this point, the radius of curvature of lower edge  19  shown in  FIG. 1  is r 19 , while the radius of curvature of upper edge  17  is r 17 . The radius of curvature may be, for example, from about 0.1 inch to about 1 inch (0.25 cm-2.5 cm). In other embodiments, the upper and lower edges  17 ,  19  may define a curve that is non-circular and, therefore, has a changing radius of curvature. Examples may include curves that are parabolic ellipsoidal or hyperbolic in shape.  FIGS. 1C-1D  illustrate a fastener component  11  with parabolic upper and lower edges  17 ′, 19 ′.  
         [0076]     In some embodiments, the maximum height H ( FIG. 1 ) of the engageable elements  12  above the sheet-form base  14  at the apexes A 1 , A 2  is, for example, from about 0.001 inch to about 0.250 inch (0.0025 cm-0.64 cm). In other embodiments, where the engageable elements resemble “fish scales,” the height H is, for example, from about 0.001 inch to about 0.050 inch (0.0025 cm-0.13 cm). “Fish scale” engageable elements are useful, for example, when maximum flexibility is desired or when the application requires a low degree of skin irritability, for example, when the fastener component is fixed to a garment of clothing.  
         [0077]     In some embodiments, a maximum length L of the engageable elements  12  in the direction of the rows is, for example, from about 0.05 inch to about 1.0 inch (0.13 cm-2.5 cm), while the maximum width W in the engaging direction along the sheet-form base is, for example, from about 0.005 inch to about 0.25 inch (0.013 cm-0.64 cm). In some embodiments, the spacing S between rows in the engaging direction, measured along the sheet-form base from an end of a row to the beginning of an adjacent row is, for example, from about 0.005 inch to about 0.25 inch (0.13 cm-0.64 cm).  
         [0078]     Referring to  FIGS. 2-2B , each engageable element  12  defines angles α and β with respect to sheet-form base  14 . Referring now particularly to  FIG. 2A , angle α is the angle formed between the top surface of the sheet-form base and the top surface of the engageable element. Referring to  FIGS. 2 and 2 B, lower edge  19  is not directly below upper edge  17 , but is offset, the offset defining an undercut angle β. Referring particularly to  FIG. 2B , angle β is the angle formed between a line L 1  connecting upper edge  17  to lower edge  19  in a plane P E  in the engaging direction ( FIG. 1 ) that is perpendicular to the sheet-form base, and a line L 2  in the same plane that connects upper edge  17  to the sheet-form base. In some embodiments, angle α is, for example, from about 5° to about 45°, while angle β is, for example, from about 10° to about 45°. The presently preferred embodiment has an α angle to 30° and a β equal to 15°.  
         [0079]     Fastener components having engageable elements like those shown in  FIG. 1  are useful for engaging, for example, similar fastener components, forming a high shear strength fastener system. Applications and methods of forming the components will be discussed further below.  
         [0080]     Referring to  FIGS. 3-3C , a high shear fastener  30  includes two flexible fastener components  10 , oriented such that the engageable elements  12  of the top fastener component  32  face the engageable elements  12  of the corresponding bottom fastener component  34 . The top fastener component  32  is further oriented so that the engageable sides  18  of elements  12  point from left to right. Bottom fastener component  34  is oriented such that engageable elements  12  extend upwardly to mate with the engageable elements  12  of the top fastener component  32 . The bottom fastener component  34  is further oriented so that the engageable side  18  of elements  12  point from right to left. Now, referring particularly to  FIG. 3A , when the bottom fastener component  34  is fixed, and the top fastener component  32  is moved in a direction indicated by arrow  36 , a high shear engagement occurs as the engageable sides  18  of the fastener elements  12  of both components restrict movement in this direction. However, when the top fastener component  32  is moved in the opposite direction, indicated by arrow  38 , no engagement of the top fastener component  32  with the bottom fastener component  34  occurs and the two components slide relatively freely past each other, making a “clicking” sound as the engageable elements slide past each other. Referring back to  FIG. 3 , top fastener component  32  and bottom fastener component  34  are also relatively free to slide past one another in the direction in which the rows of elements extent, i.e., the directions indicated by arrows  40  and  42 . Referring particularly to  FIGS. 3B and 3C , which are top views of row R 1  engaged with row R 2  ( FIG. 3 ), when row R 1  is fixed and row R 2  is moved in a direction indicated by arrow  40  or  42 , there is slight resistance to movement, as engaging elements “rise up” from wells  44  ( FIG. 3B ) through the maximum of engageable side  18  and come to rest in adjacent wells  44  ( FIG. 3C ). This feature allows for in-place fastener adjustability. As an example to further illustrate adjustability, fastener component  10  may be, for example, attached to a wall in a room with the engageable side directed upwardly toward the ceiling of the room. Another fastener component  10  may be, for example, attached to the back of a shallow, heavy rectangular object, such as a picture frame with the engageable side directed downwardly. The heavy object may now be placed on the wall and held in place by the engageable elements. While still in-place on the wall, the heavy object may be translated laterally in units of length L along the wall, rising up against gravity from wells  44  and passing over each arcuate element before coming to rest in the adjacent wells as described above. Referring now to  FIGS. 1 and 3 A, decreasing spacing S allows for finer adjustment steps. In the example above when the heavy object is a picture frame, decreasing spacing S allows for greater adjustability (smaller steps) along the height of a wall. Referring now again to  FIGS. 2A-2B  and  FIG. 3 , increasing angle α makes it more difficult to slide components  32  and  34  past each other when oriented in the high shear mode discussed above. Increasing angle β allows for enhanced robustness in peel mode. While an angle β equal to 0° will work in shear mode, it will not provide much resistance in peel mode. In the example above where the heavy object is a picture frame, the robustness translates into how easy it is to accidentally cause the picture frame to fall off the wall by bumping the frame in a direction perpendicular to the wall to which it is attached.  
         [0081]     Referring now to  FIG. 4 , a process for forming the fastener component  10  shown in  FIG. 1  is illustrated. Thermoplastic resin  50  from extruder  52  is introduced into nip 54 formed between a supporting pressure roll  56  and a mold roll  58 . Pressure in the nip causes thermoplastic resin  50  to enter blind-ended forming cavities  60  of mold roll  58  while excess resin remains about the periphery of the mold roll and is calendared to form sheet-form base  14 . As the rolls  56 ,  58  rotate in opposite directions (shown by arrows), the thermoplastic resin proceeds along the periphery of the mold roll until it is stripped by stripper roll  62 . The resulting fastener component  10  is described above. The direction of travel of the material illustrated in  FIG. 4  is referred to as the “machine direction” (MD) of the material and defines the longitudinal direction of the resulting product  10 , while the cross-machine direction (CD) is perpendicular to the machine direction. Further details regarding processing are described in Fischer, U.S. Pat. No. 4,775,310, the disclosure of which is hereby incorporated in full by reference.  
         [0082]     In another embodiment, illustrated in  FIG. 5 , an alternate technique for producing fastener component  10  of  FIG. 1  is employed. The process is similar to that described above with reference to  FIG. 4 , except only a mold roll  58  is used, i.e., no pressure roll  56  is necessary. Here, the extruder  52  is shaped to conform to the periphery of the mold roll and the extruded resin  50  is introduced directly to a gap  64  formed between the mold roll and the extruder  52 . From here, flexible fastener component  10  is stripped from the mold cavities  60  by stripper roll  62  as described above. Further details regarding this process are described by Akeno in U.S. Pat. Nos. 5,781,969 and 5,913,482, the disclosures of which are hereby incorporated in full by reference.  
         [0083]     Referring now to  FIGS. 4A-4C , a process for forming fastener components bonded to a web material is illustrated. Web material  53  is brought into nip  54  formed between roll  58  and roll  56  as discussed above. Web material can be, for example, a relatively non-porous material such as a plastic sheet material or a relatively porous textile gauze material such as a scrim material. If the web material is relatively non-porous, fastener components like that of  FIG. 4B  result. If the web material is a relatively porous material, fastener components like that of  FIG. 4C  result, as the molten resin penetrates the pores of the scrim material. Depositing molten resin upon a scrim material is discussed in U.S. patent application Ser. No. 10/688,301, filed Oct. 15, 2003, the entire content of which is hereby incorporated by reference.  
         [0084]     Other processes for forming flexible fastener component  10  are possible. For example, the processes described by Jens, U.S. Pat. No. 6,432,339, the disclosure of which is hereby incorporated in full by reference. In yet another process, flexible fastener component  10  may be formed from sheets of a pre-form material that may be, for example, pre-heated and compression molded, the heat and the pressure forming the engageable elements  12 . The advantage of this type of processing may be, for example, the use of flat, inexpensive tooling and the use of a relatively inexpensive hydraulic press. Another advantage of the compression molding process is that it allows for the use of thermoset resins that offer, for example, higher temperature stability and better chemical resistance when compared to thermoplastic materials. The disadvantage of this type of processing may be, for example, relatively low throughput since it is a batch process instead of a continuous process.  
         [0085]     Referring to  FIG. 4D , a process for forming fastener components with engageable elements on both sides of a sheet-form base is illustrated. Thermoplastic resin  50  from extruder  52  is introduced into nip  54  formed between two mold rolls  58 . Pressure in the nip causes thermoplastic resin  50  to enter blind-ended forming cavities  60  of mold rolls  58 , forming a double-sided fastener component.  
         [0086]     Referring now specifically to Box  4 , Box  4 A, Box  4 D and Box  5  of  FIGS. 4, 4A ,  4 D and  5 , respectively, additional post processing may be applied to fastener components. For example, Boxes  4 ,  4 A,  4 D and  5  may represent “flat-topping” stations as described by Provost in U.S. Pat. No. 5,953,797, the disclosure of which is hereby incorporated in full by reference. Flat-topping can, for example, increase the peel strength of fastener systems by increasing the overhang of the engageable elements.  
         [0087]     Referring now to  FIG. 6 , flat tooling can be machined to create, for example, a compression mold tool. The advantages of compression molding fastener components have been described above. Cavities  60  can be machined or burned (e.g., by EDM) into the tool. Other methods for forming cavities are known in the art.  
         [0088]     Referring to  FIG. 7 , entire mold rolls  58  or large portions  76  thereof can be machined by holding mold roll  58  on table  70  and machining its surface, for example, with a CNC milling machine  72  to form cavities  60 . The milling machine may include, for example, a dovetail cutter  74 . In comparison to forming mold rolls from machined plates, this process has the advantage, for example, of fewer parts to assemble. In addition, this process can allow for, for example, less expensive tooling, faster tooling changeover, easier tool cleaning and may eliminate or reduce flashing.  
         [0089]      FIGS. 7A-7B  show, a dovetail cutter  74  suitable for making the tooling described above. The geometry of cutter  74  can be described in terms of cutter diameter A, face width B, shank diameter C, overall length D and included angle φ. Suitable cutters may have, for example, the following dimensions:  
                                                   DIMENSION   RANGE                           A   0.125 inch-3.000 inch (0.318 cm-7.62 cm)           B   0.125 inch-2.000 inch (0.318 cm-5.08 cm)           C   0.125 inch-1.500 inch (0.318 cm-3.81 cm)           D   1.500 inch-4.000 inch (3.81 cm-10.16 cm)           φ   30-60°                        
         [0090]     Referring to  FIGS. 8-9A , a tubular fastener component is made wrapping proximal end  80  and distal end  82  of fastener component  10  toward each other, as indicated by arrows  81  and  83 , until ends  80  and  82  physically touch or only a small gap  88  remains. Joining touching ends  80  and  82  can be accomplished by using, for example, an impulse sealer or an ultrasonic welder. In other embodiments, ends  80  and  82  may be joined by filling gap  88  with an elastomeric adhesive. This method can be particularly advantageous when a flexible joint is desired. A flexible joint may be desired, for example, when the tubular structure is placed on an oversized member (not shown), for example, an insert in a reactive injection mold or injection mold. Tubular fastener component  90  includes a first open end  84  and a second open end  86 . In another embodiment, the shape of the tubular fastener is fixed in the shape shown in  FIG. 9  (i.e., gap is not closed) by heating the sheet-form base on the side opposite the engageable elements, and then holding in the shown configuration until the sheet-form base cools, thereby permanently setting the shape of  FIG. 9 . This embodiment acts like a “spring” in that it the fastener component has radial flex which allows the fastener component to be placed onto over-sized objects, for example, protrusions in molds with a larger diameter than the fastener component.  
         [0091]     Referring to  FIGS. 10-11A , tubular fastener component  100  may be formed by orienting flexible fastener component  10  so that the engageable elements  12  will extend on an outer surface of the finished tubular fastener component. The ends of fastener component  10  are then wrapped and joined as described above.  
         [0092]     Now referring to  FIG. 12 , fastener system  110  includes tubular fastener component  90  and tubular fastener component  100 , sized such that the fastener component  100  fits inside of fastener component  90 . To more fully appreciate and understand the operation of the fastener system  110 , imagine fastener component  90  fixed in space, for example, extending from a molded part. Fastener component  100  is substantially free to move over fastener component  90  in a direction indicated by arrow  112 . However, when the fastener component  100  is moved in the opposite direction as indicated by arrow  114 , a high shear strength engagement results as the engageable sides  18  of engageable elements  12  of both tubular fastener components  90  and  100  restrict movement in this direction.  
         [0093]     Referring to  FIG. 13 , a molded-in fastener component  120  is made by embedding tubular fastener compnent  90  in plastic  122 . This is done by placing tubular fastener compnent  90  on protrusion  132  of a mold insert  130 , for example, as shown in  FIG. 14 , with engageable elements  12  adjacent the outer surface of protrusion  132 . Mold insert  130  may be a component, for example, of an injection mold or a reaction injection mold (not shown). The plastic  122  that embeds the tubular fastener compnent  90  may be, for example, a thermoplastic or a thermoset. In order to keep tubular fastener compnent  90  on protrusion  132  during cycling of the mold, it can be advantageous to fill the thermoplastic resin  50  ( FIG. 4 ) that will form fastener component  90  with a magnetic material. Further details about filling thermoplastic resin with magnetic materials, for example, a ferro-magnetic filler, are described by Pollard, U.S. Pat. No. 5,945,193, and Kenney, U.S. Pat. No. 6,129,970, the disclosures of which are hereby incorporated in full by reference herein. When tubular fastener components, such as component  90  of  FIGS. 13 and 14 , are molded into a substrate, e.g., a foam bun, the height H of the engageable elements is generally minimized to avoid excessive longitudinal intrusion of material into inner portions of the tubular structure. To prevent intrusion, preferably, elements have a maximum height of less than 0.025 inch (0.635 mm), e.g., 0.010 inch (0.254 mm), or less, e.g., less than 0.005 inch (0.127 mm).  
         [0094]     Referring to  FIG. 14A , and back again to  FIG. 14 , in addition to minimizing the height of the engageable elements, another way to minimize intrusion of material longitudinally into inner portions of the tubular structure is to provide a mold protrusion  303  that includes a distal end portion  306  with a diameter larger than a nominal diameter the tubular structure  305 . The tubular structure  305  has an engageable element-free region  307  that seals against distal end portion  306 . The proximal end of protrusion  303  contains a tapered portion  309  for sealing the opposite end of tubular structure  305 . Distal end portion  306  of protrusion  303  includes a tapered lead-in  313 , and a tapered lead-off  311  to allow fastener component  305  to be easily placed onto, and removed from protrusion  303 .  
         [0095]     Referring to  FIG. 14B , another way to minimize intrusion of material longitudinally into inner portions of a tubular structure is to provide a tubular fastener  320  that includes a resilient material, e.g., an elastomer, that forms a seal  321  at a distal end of the fastener component. The proximal end of the tubular structure  320  is sealed by tapered portion  324  on protrusion  322 , as discussed above.  
         [0096]     Radial intrusion of material into inner portions of a tubular structure can be minimized, for example, by longitudinally sealing the tubular structure with an elastomer, or by thermally fusing previously opposite edges. Referring to  FIGS. 14C , another method of preventing radial intrusion of material includes overlapping opposite tapered edges  330 . Additional methods of preventing intrusion, and of attaching a fabric cover to a seat cushion, are discussed in “FASTENERS,” filed concurrently herewith, and assigned U.S. Ser. No. ______, the disclosure of which is hereby incorporated in full by reference, herein.  
         [0097]     Referring to  FIGS. 13A-13C , a fastener component, for example, fastener component  10  of  FIG. 1 , is fixed upon support  119  by, for example, using an adhesive, sewing or employing the process for forming fastener components bonded to web materials discussed above. Depending upon how the fastener component is oriented on support  119 , fastener components  121  and  123  of  FIGS. 13A and 13B , respectively, can result. Fastener component  127  results from fixing fastener component  121  upon a support  125 , for example, by stitching. Similarly, fastener component  129  is formed by fixing component  123  onto a foam support  126  by, for example, using adhesive or integrally molding component  123  onto  126 . Pushing component  127  into component  129  creates a high shear fastening system. Support  125  may be, for example, a fabric cover and foam support  126  may be, for example, a foam bun that serves as a seat. Various methods of attaching a fabric cover to a seat cushion are described in Roberts, U.S. Pat. No. 5,964,017, Wildem et al., U.S. Pat. No. 5,605,373 and Angell, U.S. Pat. No. 5,499,859, the entire disclosure of each of which is hereby incorporated in full by reference.  
         [0098]     Referring to  FIGS. 15-16 , another fastening system is illustrated for joining two sheet materials, for example, attaching an extruded plastic stud  140  to a sheet of metal  150 . Referring particularly to  FIG. 16 , extruded stud  140  has a plastic male component  142  that is integral with and extends outwardly from one side. While only one male component  142  is shown, plastic stud  140  may have a plurality of such male components  142 . Male component  142  may be formed by extrusion during the same process as making plastic stud  140  or male component  142  may be, for example, adhesive bonded at a later time. Flexible fastener component  10  that is, for example, adhesive-backed is applied to both sides of the plastic male component  142  such that the engageable sides  18  of each of the engageable elements  12  point generally in an downwardly direction, creating male fastener assembly  144 . As an alternative process, male fastener assembly  144  may be, for example, molded as a single, unitary component. Referring particularly to  FIG. 15 , sheet metal female assembly  148  includes an extruded plastic female member  146  attached to sheet metal  150 . While only one female member  146  is shown, sheet metal  150  may be attached to a plurality of such components. In addition, female member  146  may be formed, for example, by extrusion and can, therefore, be of considerable length. Flexible fastener component  10  that is, for example, adhesive-backed is applied to both sides of the plastic female member  146  such that the engageable side  18  of each of the engageable elements  12  point generally in an upwardly direction, creating female fastener component  148 . In an alternative embodiment, female fastener assembly  148  may be, for example, molded as a single, unitary component. Referring now to both  FIGS. 15 and 16 , to attach extruded plastic stud  140  to sheet metal  150 , male assembly  144  is moved in direction indicated by arrow  152  while keeping female assembly  148  fixed in place. A high shear strength engagement occurs and high force needs to be applied in a direction indicated by arrow  154  to disassemble male assembly  144  from female assembly  148 .  
         [0099]     Referring next to  FIGS. 17 and 18 , fastener component  139  includes engageable elements  140  similar to those of  FIG. 1 , and hooks  142 , 144  extending outwardly from one side of a sheet-form base  146 . In the embodiment shown in  FIG. 17 , hooks  142 , 144  extend toward and away from the viewer, respectively. In addition, loops  148  extend outwardly from the same side of the base  146  as the elements  140 . Elements  140  are positioned between hooks  142 , 144  and loops  148 . In some implementations, the elements  140 , 142  and  144  are molded at the same time using a modified version of the process described in  FIG. 4 . In this modified process, the mold roll includes a combination of the tooling described above and the tooling described in Fischer, U.S. Pat. No. 4,775,310. Tooling described in Fischer is formed by a face-to-face assembly of thin, circular plates, of thickness, for example, between about 0.004 inch and 0.250 inch (0.010 cm-0.635 cm). Some of the plates, referred to as mold rings, have cutouts in their circular peripheries that define mold cavities while others, referred to as spacer rings, have smooth circular peripheries. The sides of the spacer rings serve to close the open sides of the cutout mold cavities and to serve to create the row spacing between rows of molded features. In some implementations, the loops  148  are bonded to base  146  by using, for example, adhesive. In other embodiments, loops are fed to the nip and melt incorporated.  
         [0100]     Referring now to  FIG. 18 , a fastener system  149  that has good shear and peel performance may be formed by engaging two fastener components  139 . When a shear force F 1  is directed as shown in  FIG. 18 , fastener system  149  exhibits good shear performance due to engageable elements  140 , as discussed above. In addition, when a peel force F2 is directed as shown in  FIG. 18 , fastener system  149  exhibits good peel performance due to the engagement of hooks  142 , 144  with loops  148 .  
         [0101]     Referring to  FIG. 19 , a container  150  includes a top  152  sized to fit onto a bottom  156 . Fixed upon an inside surface of top  152  are engageable elements  154 . Also, fixed upon an outside surface of bottom  156  are engageable elements  158 . The engageable elements  154 , 158  are similar to those shown in  FIG. 1 . Engageable elements  154  are fixed upon top  152  such that the elements  154  are oriented with the engageable sides pointing up as shown. Engageable elements  158  are fixed upon bottom  156  such that the elements  158  are oriented with the engageable sides pointing down as shown. To apply or remove top  152  from bottom  156 , engageable elements  154  and vacant portions  157  are aligned, as are engageable elements  158  and vacant portions  155 . Twisting top  152  clockwise or counter clockwise allows top  152  to become “locked” onto bottom  156  as the rows of engageable elements engage one another. Engageable elements  154 , 158  may be fixed using adhesive, or injection molded during the formation of the part.  
         [0102]     Referring to  FIG. 20 , fastener component  170  includes engageable elements  172 , 174  that extend from portions of sheet-form base  176 , the portions being disposed on opposite sides of base  176 . Fastener component  174  can be made by the process of  FIG. 4D  or elements  172 , 174  can be bonded to base  176  using an adhesive. Referring to  FIG. 20A , elements  172 , 174  are oriented such that upon wrapping base  176  in the manner shown in  FIG. 21 , a tubular structure  180  results that includes a dis-engageable, high shear fastener  181 . Fastener component  170  is useful for, for example, holding insulation to pipes.  
         [0103]     Referring to  FIG. 21 , two pipes  192 , 198 , such as PVC pipes, can be joined by placing engageable elements  194 , 200  on pipes  192 , 198 . Pipe  192  includes a resilient material  196  bonded to a wall that can act as a fluidic seal. Pipe  192  is sized to accept pipe  198  and engageable elements are oriented such that pushing pipe  198  into pipe  192  creates a high shear engagement, similar to that described when discussing  FIG. 12 . A fluid tight seal results upon further pushing pipe  198  into pipe  192  as pipe  198  engages and compresses resilient material  196 . In some embodiments, the resilient material is, for example, a thermoset such as a natural rubber. In other implementations, resilient material  196  is, for example, a thermoplastic elastomer such as elastomeric PVC.  
         [0104]     Referring to  FIG. 22 , a fastener product  600 A includes an array of arcuate engageable elements  630 A integrally molded with, and extending outwardly from a base  615 A. The engageable elements each include an engageable side  633 A, and a non-engageable side  631 A. Both the upper  632 A and lower edges define curves (e.g., circular curves) such that the engageable side  633 A has a curved shape, as descrbed above in reference to FIGS.  1 ,  1 A- 1 B,  2 A- 2 B. Similar fasteners are discussed in “FASTENER PRODUCTS,” filed concurrently herewith, and assigned U.S. Ser. No. ______, the disclosure of which is hereby incorporated in full by reference herein.  
         [0105]     Referring to  FIGS. 22 and 23 , the head element  610  defines an aperture  645 . When the fastener strap  605  is inserted through the aperture  645 , the head element  610  cooperates with the fastener projections  630 A to prevent the strap  605  from retreating back through the aperture  645 . In other words, the head element  610  is configured such that it provides one-way movement through the aperture  645 . The head element  610  includes a retaining arm  658  that extends into the aperture  645 . When the strap  605  is pulled through the aperture  645  in the direction of the arrow, the first surfaces  631 A (non-engageable side) of the wedge-shaped fastener projections  630 A deflect the retaining arm  658  away from the projections  630 A allowing the strap  605  to proceed through the head element  610 . However, when the strap  605  is pulled in a direction opposite to that shown by the arrow, the second surface  633 A (engageable side) of the projection  630 A abuts and engages the retaining arm  658 . This prevents the strap  605  from exiting the head element  610 . The fastener product shown in  FIG. 23  can be used to retain articles (e.g., tubes or pipes) in a bundle. Similarly, they can be used to suspend an article or articles from a beam or other structure. In addition, the fastener products can be useful as a human restraint mechanism (e.g., handcuffs). They can be wrapped around the wrists or ankles of a person and tightly fastened to restrain the person.  
         [0106]     Referring to  FIG. 24 , an apparatus is shown that can be used to produce the fastener product shown in  FIG. 22 . Mold roll  215  includes multiple lanes of molding cavities  252  arranged across its transverse direction. Each lane of molding cavities is circumferentially separated along the mold roll  215  such that the fastener product sheet molded, when molten resin is delivered to nip N by die  205  connected to an extruder, includes multiple, longitudinally separated lanes of fastener projections. In other embodiments, the mold roll can include a continuous array of molding cavities spanning the circumferential surface of the mold roll. The mold roll  215  also includes multiple, circumferentially spaced molding recesses  250 . As a result, the fastener product sheet molded in the process includes multiple, longitudinally spaced apart head elements and/or holes defined by the head elements.  
         [0107]     Referring to  FIG. 24 , the mold roll  215  includes wedge-shaped molding cavities  252  to mold wedge-shaped fastener projections. The cavities  252  include a first planar surface that extends inward from the peripheral surface of the mold roll  215  at a decline relative to the peripheral surface. The cavities  252  include a second surface that extends inward at a decline substantially steeper than the decline of the first surface. The first and second surfaces join together at their distal ends within the cavities  252 . In some embodiments, the second surface is curved to form a projection having a curved wall.  
         [0108]     Referring to  FIG. 25 , the molding recesses  250  include an outer recessed portion  271  to form the head element and an inner unrecessed portion  272  to form the hole within the head element. The inner unrecessed portion  272  includes a recess  273  that extends inward at an angle relative to the side surfaces of the head elements for forming the restraining arm that extends from the head element. In the embodiment discussed above, the molding cavities  252  and recesses  250  are each located in the mold roll  215 . In alternative embodiments, the pressure roll  220  can define the molding recesses  250  and cavities  252 . Similarly, the recesses  250  and cavities  252  can be located, in various combinations, in both the mold roll  215  and the pressure roll  220 .  
         [0109]     Referring to  FIG. 26  and  27 , a fastener product sheet  640  formed using the apparatus shown in  FIG. 17  includes a central region  655  and two end regions  660 ,  665 . The central region  655  includes a base  615  from which multiple horizontal lanes of fastener projections  630 A extend. The edge regions  660 ,  665  include longitudinally spaced head elements  610  that define longitudinally spaced holes or apertures  645 . The fastener product sheet  640  can be separated along predetermined frangible boundaries  699  (e.g., perforated regions) to create multiple, discrete fastener products similar to the fastener product  600 A shown in  FIG. 22 . Any of the separating methods discussed above can be used to create the discrete fastener products  
         [0110]     Referring to  FIG. 28 , a tubular fastener component  350  includes a resilient material  356 , e.g., a foam, or an elastomer, sandwiched between a tubular structure  354 , and a base  352  that includes array of wedge-shaped, engageable elements extending from a first side  352 . The second side  362  of base  352  is bound to the compliant material  356 , e.g., is integral with, or is bound with an adhesive. The array of wedge-shaped, engageable elements each have an engageable side  364 , and a non-engageable side  366 , like those shown in  FIG. 1 . Structurally rigid tubular fastener component  370  with has a wall from which wedge-shaped, engageable elements extend. The orientation of the engageable elements that extend from component  370  are generally opposite of those of component  350 . The outer diameter of component  350  is oversized relative to the inner diameter of component  370 . When component  350  is inserted into component  370  in direction  372 , the resilient material allows for radial flex of the engageable elements in directions  371 , 373  as they slide past the engageable elements of component  370 , springing back into regions  374 . This spring-type action ensures good engageability of the engageable elements.  
         [0111]     Other embodiments have also been considered. For example, while fastener components having identical elements have been shown in the figures and discussed above, in some cases the fastener components may include elements having different geometries. While hollow tubular components having fastener elements on their inner and outer surfaces have been shown and discussed above ( FIG. 11 ), a solid, injection molded male part in some cases is advantageous. The hooks in the embodiment shown in  FIG. 17  may be oriented differently. For example, the hooks may all be oriented in the same direction.  
         [0112]     Other embodiments are within the scope of the following claims.