Abstract:
An improved fastener stock is comprised of a pair of longitudinal and continuous side members to which are coupled to a plurality of equidistantly spaced cross-pieces. The pair of longitudinal and continuous side members are extended in a parallel spaced relationship, and the series of cross-pieces are arranged at spaced intervals between the side members so as to connect the side members. Along at least one of the side members, a series of engagement notches are present at spaced intervals between each of the cross-pieces members, and the engagement notches are rectangular or square in shape. A method of applying a fastener to an article is provided. The method includes initially feeding a substantially continuous fastener stock from a supply, engaging at least one engagement notch, urging the fastener stock forward, feeding the fastener stock to a needle assembly, cutting a fastener from the fastener stock, and inserting the fastener into an article.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application is a Continuation-in-Part of International Application Number PCT/US2011/062189 filed Nov. 28, 2011 which claims priority from U.S. Provisional Application No. 61/420,856 filed Dec. 8, 2010, which is incorporated herein by reference in its entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention generally relates to fasteners and fastening systems, and in particular to fasteners or staples and a fastener stock configured for enabling enhanced precision and uniformity in the feeding of the fasteners to a needle assembly of a fastening system. 
     BACKGROUND OF THE INVENTION 
     Plastic fasteners or elastic staples having a flexible filament connecting enlarged side members thereof are becoming increasingly popular alternatives for attachment and securing a variety of different articles, particularly in retail and other, similar applications. For example, it has now become common for plastic fasteners to be used to attach product labels, price tags or other materials to fabric materials such as garments and apparel items. Alternatively, plastic fasteners are used as a means of securing a product or item to a hang tag or similar packaging without having to fully encapsulate the product within the packaging. Plastic or elastic fasteners can enable the products to be securely fastened to product packaging or tags without the risk of injury or damage to the product from the use of metal staples having sharp edges. In addition, the cost of the plastic fasteners typically is substantially less than other packaging methods such as metal staples, cable ties and/or twist ties. 
     Such plastic fasteners generally are applied or inserted using a fastener dispensing tool or system. Such fastener dispensing systems include hand operating tools, often referred to as “tagging guns,” and automated stapling equipment which feed and cut the fasteners from a continuously connected fastener stock supply to a needle assembly for insertion of the fasteners into an article, such as an article of clothing, etc. For example, U.S. Pat. Nos. 4,039,078 and 4,121,487 illustrate continuously connected fastener stocks and systems for dispensing plastic fasteners from such fastener stock. As indicated in these patents, the fastener stock generally is formed with a ladder-like structure including elongated side members with filaments extending therebetween at spaced intervals. The fastener stock generally can be fed or wound about a supply roll and will be fed by a feed mechanism to the needle assembly of the fastener dispensing system, whereupon the fasteners will be separated or cut away from the stock and inserted into the article. 
     In conventional systems, the feed mechanism for feeding the fastener stock to the needle assembly of the fastener dispensing system generally comprises a feed wheel or similar rotary mechanism that engages the filaments extending between the side members and pulls or urges the fastener stock forwardly to feed a next fastener into the needle assembly for cutting and insertion. Such rotary feed systems, however, typically can be somewhat bulky and can create variation in a cut location. The filaments of the fastener stock typically have a desired amount of elasticity or flexibility and thus can stretch or expand by varying amounts as the filaments are engaged by the feed wheel, causing a variation or difference in the distance that the fastener stock is pulled forward. Thus, a variation or inconsistency is created in the cut location for successive fasteners cut from the fastener stock. These inconsistencies or variation in the location at which the fasteners are cut or severed from their fastener stock leads to inconsistent and reduced sizes of the side members of the plastic fasteners that in turn can lead to improper retention of the fastener in use. Such rotating feed wheel systems also can be somewhat complex and expensive in operation. 
     Accordingly, it can be seen that a need exists for a fastener and fastener stock system that addresses the foregoing and other related and unrelated problems in the art. 
     BRIEF SUMMARY OF THE INVENTION 
     The embodiments of the present invention described below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of the present invention. 
     It is an object of the present invention to provide a new and improved supply of substantially continuous fastener stock. 
     It is yet another object of the present invention to provide fastener stock as described above that is shaped to include a pair of longitudinal and continuous side members to which are coupled to a plurality of equidistantly spaced cross-pieces. The pair of longitudinal and continuous side members are extended in a parallel spaced relationship, and the series of cross-pieces are arranged at spaced intervals between the side members so as to connect the side members. Along at least one of the side members, a series of engagement notches are present at spaced intervals between each of said cross-pieces members, and the engagement notches are rectangular or square in shape. 
     It is still another object of the present invention to provide a method of applying a fastener to an article. The method includes a step of initially feeding a substantially continuous fastener stock from a supply, wherein the fastener stock includes a pair of longitudinal and continuous side members that are linked by cross-pieces, which are extended and arranged at spaced intervals along the side members. A second step where at least one engagement notch is formed along at least one of the side members and engaged with a feed mechanism. A third step where the fastener stock is urged forwardly with the feed mechanism. A fourth step where the fastener stock is fed to a needle assembly of a fastener dispensing system. A fifth step where a fastener is cut from the fastener stock at a cut location, and a final step where the fastener is inserted into the article. 
     It is yet another object of the present invention to provide fastener stock as described above that is shaped to include a pair of longitudinal and continuous side members to which are coupled to a plurality of equidistantly spaced cross-pieces. The pair of longitudinal and continuous side members are extended in a parallel spaced relationship, and the series of cross-pieces are arranged at spaced intervals between the side members so as to connect the side members. The pair or longitudinal and continuous side members and the cross-pieces both have a flat side. Along at least one of the side members, a series of engagement notches are present at spaced intervals between each of said cross-pieces members, and the engagement notches are rectangular or square in shape. 
     It is another object of the present invention to provide paddle fastener stock as described above that is shaped to include a longitudinal and continuous side member and a plurality of paddle heads to which are coupled to a plurality of equidistantly spaced cross-pieces. The longitudinal and continuous side member and paddle heads are extended in a parallel spaced relationship, and the series of cross-pieces are arranged at spaced intervals between the side member and paddle heads so as to connect the side member and paddle heads. The longitudinal and continuous side member, paddle heads, and the cross-pieces both have a flat side. Along the side member, a series of engagement notches are present at spaced intervals between each of said cross-pieces members, and the engagement notches are rectangular or square in shape. 
     The embodiments of the present invention described below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of the present invention. 
     Other features and advantages of the present invention will become apparent to those skilled in the art from the following detailed description. It is to be understood, however, that the detailed description of the various embodiments and specific examples, while indicating preferred and other embodiments of the present invention, are given by way of illustration and not limitation. Many changes and modifications within the scope of the present invention may be made without departing from the spirit thereof, and the invention includes all such modifications. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       These, as well as other objects and advantages of this invention, will be more completely understood and appreciated by referring to the following more detailed description of the presently preferred exemplary embodiments of the invention in conjunction with the accompanying drawings, of which: 
         FIG. 1  is a perspective illustration of a length of continuously connected fastener stock; 
         FIG. 2  is a perspective view schematically illustrating the fastener stock engaged by linearly moving fingers of a feed mechanism; 
         FIG. 3  is a perspective illustration of a fastener cut from the fastener stock according to the principles of the present invention; 
         FIG. 4  is a perspective view of a fastener dispensing hand tool for applying fasteners; 
         FIG. 5A  is a side view illustrating the fastener stock engaged by linearly moving fingers utilizing a tract mechanism; 
         FIG. 5B  is a side view illustrating the fastener stock engaged by a linearly moving finger utilizing a tract mechanism; 
         FIG. 6  is a side view illustrating the fastener stock engaged by linearly moving fingers utilizing a carousel structure; 
         FIGS. 7 and 8  are side views illustrating the fasteners applied to articles of different thicknesses; 
         FIG. 9  is a perspective view of a length of continuously connected paddle fastener stock; and 
         FIG. 10  is a perspective illustration of a paddle fastener cut from the paddle fastener stock. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The apparatuses and methods disclosed in this document are described in detail by way of examples and with reference to the figures. Unless otherwise specified, like numbers in the figures indicate references to the same, similar, or corresponding elements throughout the figures. It will be appreciated that modifications to disclosed and described examples, arrangements, configurations, components, elements, apparatuses, methods, materials, etc. can be made and may be desired for a specific application. In this disclosure, any identification of specific shapes, materials, techniques, arrangements, etc. are either related to a specific example presented or are merely a general description of such a shape, material, technique, arrangement, etc. Identifications of specific details or examples are not intended to be, and should not be, construed as mandatory or limiting unless specifically designated as such. Selected examples of apparatuses and methods are hereinafter disclosed and described in detail with reference made to the figures. 
       FIG. 1  provides a perspective view of a length of continuously connected fastener stock  16  as constructed according to the teachings of the present invention. The fastener stock  16  includes a pair of longitudinal and continuous side members, or rails,  18 - 1  and  18 - 2  and plurality of equidistantly spaced cross-pieces  13 . The fastener stock  16  comprises a plurality of connected fasteners, or staples,  10  ( FIG. 3 ) 
     The side members  18 - 1  and  18 - 2  are spaced apart from one another by a desired fastener distance “d.” Along one or both of side members  18 - 1  and  18 - 2 , a series of engagement notches  25  generally will be formed. Each notch  25  will be formed at a location substantially corresponding to or in close proximity with an actual or desired cut location  22  for the fastener  10  ( FIG. 2 ). The cut locations  22  on the side members  18 - 1  and  18 - 2  should be generally aligned or parallel with one another for consistent sized fasteners  10  ( FIG. 3 ). The notches  25  will generally be on an outer side  35  of the side members  18 - 1  and  18 - 2 , facing outward and away from the cross-pieces  13 . The side members  18 - 1  and  18 - 2  can be of various lengths, intervals and thicknesses. 
     The cross-pieces  13  extend between the side members  18 - 1  and  18 - 2 , connecting the side members  18 - 1  and  18 - 2  together. The cross-pieces  13  are arranged at spaced intervals along the side members  18 - 1  and  18 - 2 . The cross-pieces  13  may be of a thinner or reduced cross-section as compared to the side members  18 - 1  and  18 - 2 . Additionally, the desired approximate stretch range of the cross-pieces  13  can be varied depending upon the desired application of the fastener  10  ( FIG. 3 ). The cross-pieces  13  can be of various lengths, intervals and thicknesses. 
     Fastener stock  16  differs principally from prior art fastener stock in that fastener stock  16  includes the series of notches  25  formed along the sides of the side members  18 - 1  and  18 - 2 . Referring to  FIG. 2 , the notches  25  on the side member  18 - 2  assist in severing the fastener stock  16  at the proper cut location  22  to ensure consistent cutting of each fastener  10  ( FIG. 3 ). For example, each notch  25  can be aligned with the cut location  22 , or can be off-set, shifted approximately one pitch away, from the cut location  22 . Typically, the notches  25  are approximately located at a midpoint between successive cross-pieces  13 . The notches  25  further are shown as being substantially square or rectangular; however, other notch configurations also can be provided. 
     As  FIG. 2  indicates, the notches  25  in the side member  18 - 2  of the fastener stock  16  can be engaged by one or more linearly moving fingers, or pusher mechanisms,  26  of a feeding system  27  of the fastener dispensing system. Thus, instead of utilizing a rotary wheel that engages the cross-pieces  13 , which can stretch or bend due to their inherent flexibility; the present invention enables the linearly moving fingers  26  to engage the side members  18 - 1  and  18 - 2  to feed the fastener stock  16  to a needle assembly  21  ( FIG. 4 ). Unlike the cross-pieces  13 , the side members  18 - 1  and  18 - 2  typically have less flexibility or range of stretching in their longitudinal direction indicated by arrow M. As a result, the side members  18 - 1  and  18 - 2  can provide enhanced consistency in engagement and forward movement by the linearly moving fingers  26  of the feed system  27 . In addition, the notches  25  in the side members  18 - 1  and  18 - 2  assist in ensuring that consistently sized fasteners  10  ( FIG. 3 ) are cut, engaged and inserted to a needle of a needle assembly  21  ( FIG. 4 ). 
     Referring to  FIG. 3 , the severed fastener  10  is shown. By severing side members  18 - 1  and  18 - 2  ( FIGS. 1 and 2 ) at the cut location  22  near the notches  25  and between successive cross-pieces  13  ( FIGS. 1 and 2 ), a plurality of individual plastic fasteners  10  can be produced from the fastener stock  16  ( FIGS. 1 and 2 ). The fastener  10  comprises a pair of cross-bars  14 - 1  and  14 - 2  that are interconnected by a thin, flexible filament  23 . Cross-bars  14 - 1  and  14 - 2  are derived from side members  18 - 1  and  18 - 2  ( FIGS. 1 and 2 ), respectively, and filament  23  is derived from a corresponding cross-piece  13  ( FIGS. 1 and 2 ). Depending upon the desired size, the fastener  10  may consist of cross-bars  14 - 1  and  14 - 2  with notches  25  present. 
     The fastener stock  16  ( FIGS. 1 and 2 ) is generally formed by an extruding or molding process of a plastic or synthetic material such as polypropylene, polyurethane, nylon, polyvinyl chloride, or other similar durable, flexible thermo-plastic or elastomeric materials. Preferably, the plastic or synthetic material of the fastener will be both sufficiently flexible along the filaments  23 , and sufficiently stiff along its cross-bars  14 - 1  and  14 - 2  so that the fastener  10  can be easily inserted and pushed through a needle slot of the needle assembly  21  ( FIG. 4 ). In addition, the cross-bars  14 - 1  and  14 - 2  ( FIG. 3 ) of the fastener  10  must be a sufficient size and/or length to function properly and securely hold the article so that the fastener  10  has sufficient strength to hold or be retained within garments, paper, fabrics or other articles. 
     From the manufacturing process by which the fastener stock  16  ( FIGS. 1 and 2 ) is formed, a transverse cross-section of cross-bars  14 - 1  and  14 - 2  and flexible filament  23  are generally in the form a flattened semi-ellipse, or flattened semi-oval, that includes a flat bottom surface on sides  34 - 1 ,  34 - 2 , and  34 - 3 . This creates a D-shaped profile with opposing inner and outer surfaces that are generally flat with a rounded top surface. However, it is to be understood that the transverse cross-section of each of side members  18 - 1  and  18 - 2  and cross-pieces  13  could be modified without departing from the spirit of the present invention. 
     As indicated in  FIG. 4 , the fastener stock  16  can be stored or wound about a storage reel  17  for feeding to the fastener dispensing system. The fastener stock  16  of the present invention may have a particular elasticity, which allows the fastener stock  16  to be wound upon itself and to travel through the needle assembly  21 . To attach the fastener  10  ( FIG. 3 ) to an article, the fastener stock  16  is fed from a supply such as the storage reel  17 . As indicated by arrow M, the notches  25  ( FIG. 1-3 ) along the side members  18 - 1  and  18 - 2  are engaged in a forward direction by the feed mechanism  27 . The feed mechanism  27  consists of the linearly moving fingers  26  that engage the notches  25  ( FIGS. 1-3 ). Similarly, the fastener stock  16  is urged in the forward direction by the feed mechanism  27 . The fastener stock  16  is then fed to the needle assembly  21  of the fastener dispensing system, which is depicted as a hand tool  11  in  FIG. 4 . The individual fasteners  10  ( FIG. 3 ) are severed from the fastener stock  16  at the cut locations  22  ( FIGS. 1 and 2 ) along the side members  18 - 1  and  18 - 2 . The notches  25  ( FIGS. 1-3 ) assist in determining the cut locations  22  ( FIGS. 1 and 2 ) for the individual fasteners  10  ( FIG. 3 ). Typically, the cut locations  22  ( FIGS. 1 and 2 ) will be around the notches ( FIGS. 1-3 ) and approximately centered between the cross-pieces  13 . Once cut, the fastener  10  ( FIG. 3 ) is inserted into the article by the needle assembly  11 . In addition to the hand tool  11 , the fastener stock  16  may be utilized by any complimentary fastener dispensing system such as a variable needle stapling assembly. 
     In addition to the feed mechanism  27  ( FIG. 4 ) described,  FIG. 5A  demonstrates how multiple linearly moving fingers  26 A,  26 B and  26 C engage the notches  25  on the fastener stock  16  toward the needle assembly  21  ( FIG. 4 ). The linearly moving fingers  26 A,  26 B and  26 C can be mounted on a track  32  that is incrementally indexed forwardly, indicated by arrow N, with each activation of the needle assembly  21  ( FIG. 4 ). Immediately before the fastener stock  16  reaches the needle assembly  21  ( FIG. 4 ), the linearly moving fingers  26 A,  26 B and  26 C disengage with the notches  25 . Once disengaged, the linearly moving fingers  26 A,  26 B and  26 C can be retracted in an opposite direction, indicated by arrow R. A notch  25 B in the fastener stock  16  continues to travel forward to the needle assembly  21  ( FIG. 4 ), and the linearly moving fingers  26 A,  26 B and  26 C move into engagement with a next set of notches  25 A. 
     In addition to the embodiment described in  FIG. 5A ,  FIG. 5B  depicts only a single linearly moving finger  26 D to engage the notch  25  of the fastener stock  16 . The single linearly moving finger  26 D is mounted to a track  32 A that is incrementally indexed forwardly, indicated by arrow N 1 , with each activation of the needle assembly ( FIG. 4 ). Immediately before the fastener stock  16  reaches the needle assembly  21  ( FIG. 4 ), the linearly moving finger  26 D disengages with the notch  25 . Once disengaged, the linearly moving finger  26 D can be retracted in an opposite direction, indicated by arrow R 1 . A notch  25 D in the fastener stock  16  continues to travel forward to the needle assembly  21  ( FIG. 4 ), and the linearly moving finger  26 D moves into engagement with a next notch  25 B. 
     Alternatively in  FIG. 6 , one or more linearly moving fingers  26 D can be mounted on an elliptical belt or carousel structure  33  that incrementally moves the linearly moving fingers  26 D forward as indicated by arrow F, and thus the fastener stock  16  moves forwardly along a desired length of linear travel. Immediately before the fastener stock  16  reaches the needle assembly  21  ( FIG. 4 ), the linearly moving fingers  26  disengages with the notches  25 . Once disengaged, the linearly moving fingers  26  are disengaged and move along a return path. A notch  25 E in the fastener stock  16  continues to travel forward to the needle assembly  21  ( FIG. 4 ), and the linearly moving fingers  26 D move into engagement with a next notch  25 F. 
     In addition to the embodiments described, other feed systems may be utilized including a rotary wheel type feed mechanism for the fastener dispensing system. 
     Once the fastener stock  16  is cut, the severed fastener  10  ( FIG. 3 ) is inserted into articles using the fastener dispensing system.  FIGS. 7 and 8  illustrate the attachment of the fastener  10  in different configurations to secure stacks of articles  29  of varying thicknesses and shapes. In  FIG. 7 , the fastener  10  is securing two stacks of articles  29 , while in  FIG. 8 , the fastener  10  is securing eight stacks of articles  29 . In  FIGS. 7 and 8 , the cross-bars  14 - 1  and  14 - 2  secure an article back  30  while the filament  23  punctures through the stacks of articles  29  and wraps around an article front  31 . The filament  23  provides flexibility and a desired approximate amount of stretch to the fastener  10 , which enables use in different fastening configurations.  FIGS. 7 and 8  demonstrate how the fastener  10  may be used to secure stacks of articles  29 ; however, the fastener  10  may be used in a variety of applications including packaging and tagging materials. 
     Additionally, while the fastener  10  ( FIG. 3 ) of the present invention generally has been illustrated as the plastic staple or T-end type fastener, various plastic fasteners of other configurations such as paddle fasteners and loop fasteners can also be formed in accordance with the principles of the present invention. 
       FIG. 9  provides a perspective view of a length of continuously connected paddle fastener stock  37 . The paddle fastener stock  37  includes one longitudinal and continuous side member, or rail,  18 - 3 , a plurality of paddle heads  36 , and plurality of equidistantly spaced cross-pieces  13 - 1 . The paddle fastener stock  37  comprises a plurality of connected paddle fasteners  41  ( FIG. 10 ) 
     The paddle heads  36  and the side member  18 - 3  are spaced apart from one another by a desired fastener distance “p” and are parallel to one another. Along the side member  18 - 3 , a series of engagement notches  39  generally will be formed. Each notch  39  will be formed at a location substantially corresponding to or in close proximity with an actual or desired cut location  22  for the paddle fastener  41  ( FIG. 10 ). The cut locations  22  on the side member  18 - 3  should be generally aligned or parallel with one another for consistent sized paddle fasteners  41  ( FIG. 10 ). The notches  39  will generally be on an outer side  35 - 1  of the side member  18 - 3 , facing outward and away from the cross-pieces  13 - 1 . The side member  18 - 3  can be of various lengths, intervals and thicknesses. 
     The paddle heads  36  are interconnected along a rectangular side portion  42 . The paddle heads  36  are typically rectangular in shape and may have rounded or pointed corners. The paddle heads  36  are connected to the cross-piece  13 - 1  by attaching near a midpoint  43  along an inner wall  39  of the paddle head  36 . The paddle heads  36  can be of various lengths, intervals and thicknesses. 
     The cross-pieces  13 - 1  extend between the side member  18 - 3  and the paddle heads  36 , connecting the side member  18 - 3  and the paddle heads  36  together. The cross-pieces  13 - 1  are arranged at spaced intervals along the side member  18 - 3  and paddle heads  36 . The cross-pieces  13 - 1  may be of a thinner or reduced cross-section as compared to the side member  18 - 3 . Additionally, the desired approximate stretch range of the cross-pieces  13 - 1  can be varied depending upon the desired application of the paddle fastener  37  ( FIG. 10 ). The cross-pieces  13 - 1  can be of various lengths, intervals and thicknesses. 
     Referring to  FIG. 10 , the severed paddle fastener  41  is shown. By severing the side member  18 - 3  ( FIG. 9 ) and paddle heads  36  ( FIG. 9 ) at the cut locations  22  near the notches  39  and between successive cross-pieces  13 - 1  ( FIG. 9 ), a plurality of individual plastic paddle fasteners  41  can be produced from the paddle fastener stock  37  ( FIG. 9 ). The paddle fastener  41  comprises a cross-bar  14 - 3  and a rectangular portion  38  that are interconnected by a thin, flexible filament  23 - 1 . Cross-bar  14 - 3  is derived from side member  18 - 3  ( FIG. 9 ), and filament  23 - 1  is derived from a corresponding cross-piece  13 - 1  ( FIG. 9 ). The rectangular portion  38  is derived from the interconnected paddle heads  36  ( FIG. 9 ) along the rectangular side portion  42  ( FIG. 9 ). Depending upon the desired size, the paddle fastener  41  may consist of cross-bar  14 - 3  with notches  39  present. 
     A transverse cross-section of cross-bar  14 - 3 , rectangular portion  38 , and flexible filament  23 - 1  are generally in the form a flattened semi-ellipse, or flattened semi-oval, that includes a flat bottom surface on sides. This creates a D-shaped profile with opposing inner and outer surfaces that are generally flat with a rounded top surface. However, it is to be understood that the transverse cross-section of each of side member  18 - 3  ( FIG. 9 ) and cross-pieces  13 - 1  ( FIG. 9 ) could be modified without departing from the spirit of the present invention. 
     Similar to the fastener stock  16  ( FIG. 1 ), the paddle fastener stock  37  ( FIG. 9 ) may be used by fastener dispensing systems. 
     It will thus be seen according to the present invention a highly advantageous notched fastener has been provided. While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it will be apparent to those of ordinary skill in the art that the invention is not to be limited to the disclosed embodiment, and that many modifications and equivalent arrangements may be made thereof within the scope of the invention, which scope is to be accorded the broadest interpretation of the appended claims so as to encompass all equivalent structures and products. 
     The inventors hereby state their intent to rely on the Doctrine of Equivalents to determine and assess the reasonably fair scope of their invention as it pertains to any apparatus, system, method or article not materially departing from but outside the literal scope of the invention as set out in the following claims.