Abstract:
A method of producing a fastener product having a multiplicity of fastener elements extending from a base. The method includes introducing molten resin to the circumferential surface of the mold roll under pressure conditions and forcing some of the resin into molding cavities to mold an array of fastener elements integrally with resin disposed at the circumferential surface of the mold roll.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application is a divisional of U.S. patent application Ser. No. 10/952,104, filed Sep. 28, 2004, which is incorporated by reference herein. 
     
    
     TECHNICAL FIELD  
       [0002]     This invention relates to fastener products, and to methods and apparatuses for the production of fastener elements.  
       BACKGROUND  
       [0003]     Fastener products can be formed in a continuous process using an apparatus, which includes, among other things, a mold roll. Such mold rolls typically are comprised of multiple, thin plates that are stacked together. Along a circumferential surface of each plate molding surfaces are etched or otherwise formed within the plates. When the plates are aligned along a central axis, the molding surfaces of the plates cooperate with adjacent, flat plates to define very small molding cavities. These cavities are often hook-shaped. Generally, the fastening hooks are formed in the machine direction (i.e., the longitudinal direction of the resulting fastener product).  
         [0004]     It is also possible to form fastener elements using an injection mold having multiple plates stacked together. Many of the plates cooperate with adjacent flat plates to define cavities. Unlike conventional mold rolls, conventional injection molding is a discrete shot molding process (i.e., a discontinuous linear movement).  
         [0005]     To form fastener elements using a mold roll or injection mold, molten resin is forced into the cavities. The molten resin is then allowed to cool and harden while within the cavity. Finally, the hardened resin is stripped from the cavity exposing newly molded projections extending from a newly formed base.  
         [0006]     Due to the configuration of plates in conventional mold rolls, it is much easier to mold fastener elements oriented in the machine direction (i.e., the longitudinal direction of the fastener product) than in other directions. However, fastener element heads overhanging in a cross-machine direction would be useful in some applications.  
         [0007]     Conventional mold rolls are expensive, and damage to cavities within the conventional mold roll frequently results in costly repairs or even replacement of the entire mold roll. Due to the mold roll configuration, it is difficult and time-consuming to repair or replace the affected plate or plates.  
       SUMMARY  
       [0008]     In one aspect of the invention, a molding apparatus for forming a sheet-form fastener product includes a mold roll that is rotatable about an axis of rotation and has a circumferential surface defining a plurality of apertures therein. The apertures extend inward from the circumferential surface of the mold roll. A plurality of inserts, each having a first end and a second end, are retained within corresponding apertures of the mold roll such that the first end of each insert is directed toward the circumferential surface of the mold roll. The inserts have surfaces that at least partially define blind molding cavities shaped to mold, from molten resin forced into the molding cavities from the circumferential surface of the mold roll, an array of fastener elements having overhanging heads for releasable engagement with a mating fastener product.  
         [0009]     In another aspect of the invention, a method of producing a fastener product having a multiplicity of fastener elements extending from a base includes providing a mold roll having a circumferential surface defining an array of apertures. The apertures extend inward from the circumferential surface. Inserts are disposed within the apertures. The inserts have surfaces at least partially defining blind molding cavities. Molten resin is introduced to the circumferential surface of the mold roll under pressure conditions, forcing some of the resin into the molding cavities to mold an array of fastener elements integrally with resin disposed at the circumferential surface of the mold roll. And then, the resin is stripped from the mold roll.  
         [0010]     Embodiments may include one or more of the following.  
         [0011]     In some embodiments, the apertures extend along the circumferential surface of the mold roll in a direction substantially parallel to the axis of rotation of the mold roll.  
         [0012]     In certain embodiments, the apertures extend from a first side of the mold roll to a second side of the mold roll.  
         [0013]     In some embodiments, the molding cavities are completely defined within the inserts.  
         [0014]     In certain embodiments, multiple molding cavities are completely defined within each insert.  
         [0015]     In certain embodiments, first molding cavities are defined between first sides of the inserts and the mold roll. In some embodiments, second molding cavities are defined between second sides of the inserts and the mold roll. In certain embodiments, at least some of the first molding cavities include crook portions and at least some of the second molding cavities include crook portions. In some embodiments, the crook portions of the first molding cavities face in a direction substantially opposite the crook portions of the second molding cavities. In certain embodiments, the crook portions of the first and second molding cavities face in a direction transverse to the mold roll.  
         [0016]     In certain embodiments, the molding cavities extend from first sides of the inserts to second sides of the inserts.  
         [0017]     In some embodiments, the inserts comprise an upper portion and a lower portion, the lower portion including a first segment extending transversely beyond a first side of the mold roll and a second segment extending transversely beyond a second side of the mold roll.  
         [0018]     In certain embodiments, a first retainer cap is secured to the first side of the mold roll and a second retainer cap secured to the second side of the mold roll. The retainer caps have inner portions conforming to the first and second segments of the inserts to retain the inserts within the apertures.  
         [0019]     In some embodiments, each of the inserts has a width of about 0.01 inch to about 0.125 inch.  
         [0020]     In certain embodiments, the mold roll comprises a sleeve having an inner surface, and the array of apertures extend from the inner surface to the circumferential surface of the sleeve.  
         [0021]     In certain embodiments, the molding cavities are defined by perimeter portions of the inserts and the mold roll.  
         [0022]     In some embodiments, multiple molding cavities are defined by the perimeter portion of each insert and the mold roll.  
         [0023]     In certain embodiments, each of the multiple molding cavities includes a crook portion extending in the same direction along the insert.  
         [0024]     In some embodiments, a first molding cavity is defined by a first perimeter portion of each insert and the mold roll, and a second molding cavity is defined by a second perimeter portion of each insert and the mold roll, the second perimeter portion being substantially opposite the first perimeter portion.  
         [0025]     In certain embodiments, the first molding cavity and the second molding cavity include crook portions, and the crook portion of the first molding cavity faces in a direction along the insert opposite the crook portion of the second molding cavity.  
         [0026]     In some embodiments, the first molding cavity and the second molding cavity include crook portions, and the crook portions of the first and second molding cavities face in the same direction along the insert.  
         [0027]     In certain embodiments, the mold roll includes a mandrel, and the sleeve is disposed around the mandrel.  
         [0028]     In certain embodiments, the inserts include first portions and second portions. The first portions of the inserts are positioned within first portions of the apertures, and the second portions of the inserts are positioned within second portions of the apertures.  
         [0029]     In certain embodiments, the first portions of the inserts and apertures are substantially cylindrical and the second portions of the inserts and apertures are substantially disk-shaped, and the second portions having a larger diameter than the first portions.  
         [0030]     In certain embodiments, bottom surfaces of the second portions of the inserts are shaped to conform to the mandrel.  
         [0031]     In certain embodiments, the inserts are configured to be positioned within the apertures in any of a plurality of orientations.  
         [0032]     In certain embodiments, the resin is introduced into a nip defined by the mold roll and an adjacent pressure device.  
         [0033]     In certain embodiments, the pressure device comprises a counter-rotating pressure roll.  
         [0034]     In certain embodiments, the pressure device comprises an extruder that extrudes the resin into the nip.  
         [0035]     In certain embodiments, the nip is defined by the mold roll and an arcuate shaped housing of the extruder.  
         [0036]     In certain embodiments, the inserts include an upper portion and a lower portion, the lower portion including a first segment extending transversely beyond a first side of the mold roll and a second segment extending transversely beyond a second side of the mold roll.  
         [0037]     In certain embodiments, a first retainer cap is secured to the first side of the mold roll, and a second retainer cap is secured to the second side of the mold roll. The retainer caps have inner portions conforming to the first and second segments of the inserts to retain the inserts within the apertures.  
         [0038]     In certain embodiments, the mold roll includes a sleeve having an inner surface, and the array of apertures extends from the inner surface to the circumferential surface of the sleeve.  
         [0039]     In certain embodiments, the sleeve is disposed around a mandrel to retain the inserts within the apertures.  
         [0040]     Embodiments may include one or more of the following advantages.  
         [0041]     The inserts may be oriented in any radial direction within the apertures in some cases. The inserts can be arranged to product cross-direction fastener hooks. The inserts can be arranged to produce non-directional fastener products (e.g., products that provide peel and shear resistance in substantially every direction along the base of the product). In some cases, the inserts can be removed from the apertures, which allows for easy cleaning, repair, and replacement of the inserts.  
         [0042]     The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims. 
     
    
     DESCRIPTION OF DRAWINGS  
       [0043]      FIG. 1  is a side view of a first apparatus for making fastener products.  
         [0044]      FIG. 2  is a cross-sectional view of a second apparatus for molding fastener products.  
         [0045]      FIG. 3  is a cross-sectional view of a first mold roll.  
         [0046]      FIG. 4  is a broken perspective view of a region of the outer circumference of the mold roll of  FIG. 3 .  
         [0047]      FIG. 5  is a cross-sectional view of an assembled mold roll showing one means of blade retention.  
         [0048]      FIG. 6  is a perspective view of a section of an insert blade.  
         [0049]      FIG. 7  is a perspective view of a section of another insert blade.  
         [0050]      FIG. 8  is a perspective view of a section of a two-piece insert blade.  
         [0051]      FIG. 9  is a broken perspective view of a fastener product.  
         [0052]      FIG. 10  is a perspective view of a fastener product.  
         [0053]      FIG. 11  is a broken perspective view of a second mold roll with plug inserts.  
         [0054]      FIG. 12  is a cross-sectional view taken along line  11 — 11  in  FIG. 10 .  
         [0055]      FIG. 13  is a perspective view of one of the inserts shown in  FIG. 10 .  
         [0056]      FIG. 14  is a perspective view of a plug insert with two cavities at its circumference.  
         [0057]      FIG. 15  is a perspective view of a two-piece plug insert.  
         [0058]      FIG. 16  is a broken perspective view of a fastener product produced with the mold roll of  FIG. 11 . 
     
    
     DETAILED DESCRIPTION  
       [0059]     Referring to  FIG. 1 , an apparatus  215  for making fastener products includes a molding apparatus  50 , an extruder  220 , a pressure roll  225 , a stripping roll  230 , and a sheet-form material  231 . The apparatus  215  can be used to mold various types of fastener elements, such as fastener hooks.  
         [0060]     During use of apparatus  215 , sheet-form material  231  is held in tension between a roll  232  of sheet-from material  231 , mold roll  55 , and stripping roll  230 . Sheet-form material  231  may be comprised of one or more of several suitable materials. For example, sheet-form material  231  may be a loop material, a non-woven fabric, a reinforcing scrim, a porous material, paper, or foam.  
         [0061]     Referring briefly to  FIG. 3 , molding apparatus  50  is comprised of a mold roll  55  and a plurality of inserts  60 . Mold roll  55  includes an array of apertures  70  extending inward from a circumferential surface  65  toward an axis of rotation  75 . Inserts  60 , which at least partially define multiple molding cavities  130  (shown in  FIG. 4 ), are retained within apertures  70 , as described below.  
         [0062]     Referring again to  FIG. 1 , mold roll  55  is positioned adjacent pressure roll  225  such that their axes of rotation  75 ,  275  are substantially parallel to one another. A nip N is created between circumferential surface  65  of mold roll  55  and an adjacent surface of pressure roll  225 . Mold roll  55  and pressure roll  225  rotate counter to one another, which creates a large amount of pressure within nip N.  
         [0063]     Extruder  220  extrudes a molten resin  235  into a nip N where it meets sheet-form material  231 . Molten resin  235  may comprise one or more of various thermoplastics and other resins. A high density polyethylene, such as Exxon Mobil #6908, can be useful for some applications. Other suitable materials include low density polyethylene (LDPE), polypropylene, and nylon, for example.  
         [0064]     As sheet-form material  231  and molten resin  235  are conveyed through nip N, the high nip pressure forces some of the molten resin  235  into cavities  130  to mold an array of fastener elements  162  while the remainder of molten resin  235  is compressed between circumferential surface  65  and an adjacent surface of pressure roll  225  to form a common base  240  from which fastener elements  161  extend. In addition, the high nip pressure may bond common base  240  to sheet-form material  231 . However, other suitable bonding methods may also be used. For example, a heat-sensitive adhesive may be applied to one side of sheet-form material  231  and heat may be applied at a later time to adhesively bond common base  240  to sheet-form material  231 .  
         [0065]     After molten resin  235  has been forced into cavities  130 , molten resin  235  is allowed to cool and harden within cavities  130 . Mold roll  55  and pressure roll  225  may be internally cooled by water, for example, to facilitate the cooling of molten resin  235 . After cooling and hardening, resin  235  has a shape permanently corresponding to the shape of cavities  130 . In particular, molten resin  235  can be in the shape of a fastener element, such as a hook (e.g., a J-hook, a palm-tree-shaped hook, or a mushroom-shaped hook).  
         [0066]     Sheet-form material  231  is then conveyed along mold roll  55  toward stripping roll  230 . And then, sheet-form base  231  is conveyed around stripping roll  230 . This causes some of fastener elements  162 , which have been allowed to cool and harden, to be stripped from cavities  130 . At this point, a fastener product having an array of fastener elements  162  extending from common base  240  is exposed.  
         [0067]     Referring to  FIG. 2 , an alternative apparatus  216  for producing fastener products  161  includes molding apparatus  50 , an extruder  220 , an extruder housing  245 , stripping roll  230 ,and sheet-form material  231 . As represented in  FIG. 3 , molding apparatus  50  includes mold roll  55  and a plurality of inserts  60 . Mold roll  55  defines multiple apertures  70  therein, and a plurality of inserts  60  are retained within apertures  70  to define cavities  130  (shown in  FIG. 4 ).  
         [0068]     Extruder housing  245  is disposed around extruder  220 . Extruder housing  245  is arcuate-shaped to define a predetermined gap  250  between extruder housing  245  and circumferential surface  65  of mold roll  55 . Molten resin  235  is extruded through extruder  220  and into gap  250 .  
         [0069]     In this embodiment, sheet-form material  231  is preferably a porous material. As sheet-form material  231  is conveyed around mold roll  55 , extruder  220  forces molten resin  235  both onto and through sheet-form material  231 . Due to the porosity of sheet-form material  231 , some of resin  235  passes through sheet-form material  231  and into cavities  130  to form fastener elements  162 , while the remainder of resin  235  adheres to sheet-form material  231  to form common base  240  from which fastener elements  162  extend. Molten resin  235  is allowed to cool and harden before being stripped out of cavities  130  by stripping roll  230  to expose a newly formed fastener product having fastener elements  162  extending from common base  240 .  
         [0070]     As shown in  FIG. 3 , molding apparatus  50  includes a mold roll  55  and a plurality of inserts, blades, or plugs  60 . Mold roll  55  defines an array of apertures, slots, or bores  70 , which extend inward from circumferential surface  65  toward axis of rotation  75 . In some embodiments, bores  70  extend substantially perpendicular to the circumferential surface  65 . In certain embodiments, bores  70  extend at an angle of less than about 90 degrees (e.g., less than about 70 degrees or less than about 50 degrees) relative to circumferential surface  65 . The shape of apertures  70  may vary considerably. As detailed below, apertures  70  may be cylindrical or rectangular, for example. However, the shape of apertures  70  should not be limited to the described embodiments.  
         [0071]     Apertures  70  may be created within mold roll  55  using any of various suitable methods, such as wire EDM, plunge EDM, micro machining, laser cutting, and/or photo etching.  
         [0072]     As shown in  FIG. 4 , slots  70 A extend from one side  80  of mold roll  55 A to an opposite side  85  of mold roll  55 A. In this embodiment, slots  70 A are narrow relative to the diameter of mold roll  55 A. For example, slots  70 A can have a width of about 0.01 inch to about 0.125 inch.  
         [0073]     Blades  60 A are retained within slots  70 A. One end  86 A of each blade  60 A is directed toward circumferential surface  65  and another end  87 A is directed toward axis of rotation  75 . End  86 A, which is directed toward circumferential surface  65 , can be substantially aligned with circumferential surface  65 . This helps to form a smooth upper surface of common base  240  (shown in  FIGS. 1 and 2 ). Blades  60 A can have a width between about 0.01 inch and 0.125 inch.  
         [0074]     Various suitable methods of retaining blade  60 A within slot  70 A may be used. Referring to  FIG. 5 , for example, blade  60 A includes an upper portion  90  and a lower portion  95 . Lower portion  95  is wider than upper portion  90  such that a segment  100  of lower portion  95  protrudes transversely beyond a first side  80  of mold roll  55 A and another segment  105  of lower portion  95  protrudes transversely beyond a second side  85  of mold roll  55 A. Retaining caps  110 ,  115  are coupled to sides  80 ,  85  of mold roll  55 A. Inner surfaces  120 ,  125  of retaining caps  110 ,  115  are grooved to accommodate protruding segments  100 ,  105  of blade  60 A to retain blade  60 A radially within slot  70 A. Thus, when caps  110 , 115  are coupled to mold roll  55 A, blades  60 A are secured in both the lateral and radial direction of mold roll  55 A.  
         [0075]     Retaining caps  110 ,  115  and mold roll  55 A can be coupled using any of various suitable techniques. For example, mold roll  55 A and retaining caps  110 ,  115  may be threaded and screwed together. Alternatively or additionally they may be held in place by a compressive force applied to each of retaining caps  110 ,  115  and directed toward mold roll  55 A.  
         [0076]     Blades  60 A can be removed from slots  70 A by uncoupling retainer caps  110 ,  115  from mold roll  55 A and either sliding blades  60 A out of slots  70 A in a sideways direction or lifting blades  60 A out of slots  70 A in an upwards direction. This, for example, allows for easy replacement, repair, and cleaning of blades  60 A.  
         [0077]     Referring again to  FIG. 4 , a plurality of molding cavities  130  are defined between blades  60 A and mold roll  55 . Each of cavities  130  includes a stem portion  135  and a crook portion  140 . Fastener elements having corresponding stems and crooks may be produced when molten resin is forced into cavities  130 , allowed to harden, and then removed, as discussed above. Cavities may also be shaped differently to produce fastener stems only, palm-tree-shaped fastener elements, or mushroom-shaped fastener elements, for example.  
         [0078]     In order to partially define cavities  130 , a group of recesses are created within blade  60 A. When blade  60 A, which includes multiple recesses in one or more of its side surfaces, is inserted into slot  70 A, blade  60 A cooperates with mold roll  55 A to completely define cavities  130  in those recessed areas. In order to create those recessed areas, a small amount of material is removed from blade  60 A. Depending on the size and shape of the desired fastener element, the amount of material removed and the method of its removal may vary. Several suitable methods may be used to create recessed portions of blade  60 . For example, wire EDM, plunge EDM, micro machining, laser cutting, and/or photo etching may be used.  
         [0079]     Referring to  FIG. 6 , material may be removed from each of sides  145 A,  150 A of blade  60 A to partially define cavities  130  on each side  145 A,  150 A. Of course, material may alternatively be removed from only one of sides  145 A,  150 A to partially define cavities  130  on only one side of blade  60 A.  
         [0080]     As shown in  FIG. 7 , material may be completely removed between first side  145 B and second side  150 B of blade  60 B to partially define cavities  130 , which extend from first side  145 B completely through to second side  150 B. Typically, for through-cavities, the material removal process is performed from only one of sides  145 B,  150 B. However, material can be removed from both sides  145 B and  150 B.  
         [0081]     As shown in  FIG. 8 , molding cavities  130  may be completely defined within blade  60 C. In this embodiment, blade  60 C is comprised of a first half  155  and a second half  160 . Material is removed from an inner surface of one or both halves  155 ,  160  to provide a completely defined cavity. Halves  155 ,  160  are preferably press-fitted within slot  70 A. However, any suitable stabilization method capable of preventing movement of halves  155 ,  160  relative to one another may be used.  
         [0082]     It should be noted that blades  60 B and  60 C may be retained within slots  70 A in the same manner as discussed above with respect to blades  60 A.  
         [0083]     Referring to  FIG. 9 , molding cavities  130  can be used to form fastener elements  162  having crook portions  164 . Crook portions  164  of fastener elements  162  are designed to engage with corresponding fastener elements (not shown) in order to provide peel and shear resistance. The corresponding fastener elements may be comprised of any material susceptible to engagement with crook portions  164 . Commonly used materials, for example include loop material, non-woven fabric, and self-engaging hooks.  
         [0084]     Molding cavities  130  may be configured in various arrangements to produce fastener elements having differing characteristics. Molding cavities  130  may be arranged so that crook portions  140  face in opposite directions, as shown in  FIG. 6 . This arrangement produces a fastener product  161  A with fastener elements  162  having stem portions  163  and crook portions  164  with crook portions  164  facing in opposite directions, as shown in  FIG. 9 . When an approximately equal number of crook portions  164  face in opposite directions, fastener product  161  A will provide substantially equal peel and shear resistance in opposite directions.  
         [0085]     Referring again to  FIGS. 7 and 8 , molding cavities  30  may be arranged such that all or most of crook portions  140  face in the same direction. The resulting fastener product  161  B includes fastener elements  162  with crook portions  164  facing in the same direction, as shown in  FIG. 10 . This type of fastener product provides very little peel and shear resistance in one direction and a great deal of peel and shear resistance in the opposite direction.  
         [0086]     In some embodiments, molding cavities are arranged such that crook portions face in multiple different directions. For example, the molding cavities can be arranged such that crook portions face in substantially every direction along the base of the fastener product. The resulting fastener product, for example, can provide peel and sheer resistance in every direction along the base of the fastener product.  
         [0087]     Referring again to  FIG. 4 , slots  70 A and blades  60 A are aligned in a transverse direction of mold roll  55 . This advantageously enables molding fastener elements  162  having crook portions facing in a cross-machine direction CMD (i.e., transverse to mold roll  55  and perpendicular to the machine direction MD), as shown in  FIGS. 9 and 10 . Such orientation can be useful for resisting loads applied in a cross-machine direction, such as when the fastener tape is secured across a diaper tab, for example. However, it should be noted that slots  70 A and blades  60 A,  60 B,  60 C may be aligned in various other configurations with respect to circumferential surface  65 . For example, they may be aligned in machine direction MD or in a direction intermediary to machine direction MD and cross-machine direction CMD. Furthermore, cavities  130  may be aligned in various other configurations within blades  60 A,  60 B,  60 C.  
         [0088]     Referring to  FIG. 11 , another molding apparatus  50 B includes a mold roll  55 B and multiple inserts or plugs  60 D retained therein. Mold roll  55 B comprises a sleeve  165 , which defines an array of bores  70 B. Bores  70 B extend from circumferential surface  65  to an inner surface  170  of sleeve  165 . Bores  70 B may be of various shapes and sizes corresponding to the shapes and sizes of plugs  60 D. Bores  70 B may be created using any of various suitable methods. For example, bores  70 B may be created using drilling, etching, or EDM techniques. Bores  70 B are particularly small in diameter. For example, bores  70 B can have a diameter of about 0.05 inch to about 0.25 inch.  
         [0089]     Plugs  60 D may be retained within bores  70 B in any of various orientations, which allows for great versatility in the orientation of fastener elements produced. Plugs  60 D may be oriented to produce fastener elements having crook portions facing in one or more desired directions.  
         [0090]     Plugs  60 D can have a diameter of between about 0.05 inch and about 0.25 inch. Several suitable methods of retaining plugs  60 D within bores  70 B may be used. For example, as shown in  FIG. 12 , plug  60 D includes a cylindrical shank  175  with a flange  180  at one end. Bore  70 B is comprised of a central portion  185  and a recessed portion  190 . Central and recessed portions  185 ,  190  of bore  70 B conform with shank  175  and flange  180  of plug  60 D. Plug  60 D may be inserted into bore  70 B from the direction of inner surface  170  such that shank  175  of plug  60 D sits within central portion  185  of bore  70  and flange  180  of plug  60 D sits within recessed portion  190  of bore  70 B. Sleeve  165  is disposed around a mandrel  195  such that mandrel  195  abuts a bottom surface  200  of plug  60 D, while the second portion  180  of plug  60 D abuts a recessed inner surface  205  of sleeve  165 . Thus, plug  60 D is firmly compressed between mandrel  195  and sleeve  165 , and thereby retained within bore  70 B.  
         [0091]     Referring again to  FIG. 11 , molding cavities  130  are defined between plug  60 D and mold roll  55 B. Material may be removed from plug  60 D using any of the suitable methods discussed above in order to create recesses such that mold roll  55 B, in the areas of those recesses, partially define cavities  130 . Cavities  130  become fully defined upon inserting plug  60 D into bore  70 B.  
         [0092]     As shown in  FIGS. 13 , multiple molding cavities  130  are arranged along a perimeter surface  210  of plug  60 D. All cavities  130  face clockwise about plug  60 D, as viewed from the mold roll surface. This enables the molding of a group of fastener elements having crooks oriented in different directions. As a result, fastener product  161 C, which provides substantially equal peel and shear resistance in multiple directions, is produced (shown in  FIG. 16 ). As the number of cavities facing in any one direction increases, the amount of peel and shear resistance in that direction also increases.  
         [0093]     While the plug shown in  FIG. 13 , includes four molding cavities  130  that are substantially equally spaced about the circumference of the plug, it should be appreciated that the plug may include more than four molding cavities (e.g., six molding cavities or more). As the number of molding cavities per plug increases, the number of directions in which the resulting product provides peel and sheer resistance can also increase.  
         [0094]     Referring to  FIG. 14 , plug  60 E includes two partially defined molding cavities  130 . Molding cavities  130  are aligned opposite one another at two perimeter portions  111 ,  112  of plug  60 E. Both of crook portions  140  face in a clockwise direction about plug  60 E, as viewed from the mold roll surface. Plug  60 E, for example, can be used to produce a fastener product with substantially equal peel and shear resistance in opposite directions (similar to the product shown in  FIG. 9 ). In certain embodiments, the opposite molding cavities can be arranged about the plug such that the crook portion of one molding cavity faces in the counterclockwise direction while the crook portion of the other molding cavity faces in the clockwise direction. This configuration enables the molding of a fastener product that provides peel and shear resistance in substantially only one direction (similar to the product shown in  FIG. 10 ). In certain embodiments, two cavities  130  may be spaced apart circumferentially by about 90 degrees to produce a fastener product that provides peel and shear resistance in a longitudinal direction and in a lateral direction.  
         [0095]     As shown in  FIG. 15 , plug  60 F may completely define molding cavity  30 . Plug  60 F is comprised of two halves, a first half  213  and a second half  214 . Material is removed from one or both halves  213 ,  214  so that cavity  130  is defined when halves  213 ,  214  are joined together within bore  70 B. Plug  60 F is preferably press-fitted within bore  70 B in a manner that prevents halves  213 ,  214  from moving relative to one another. However, any suitable method of stabilization capable of preventing relative movement between halves  213 ,  214  may be used.  
         [0096]     In any of the embodiments discussed above, plugs  60 D,  60 E,  60 F may be secured in corresponding bores  70 B in any rotational orientation. As a result molding cavities  130  may be oriented in any direction relative to the machine direction of processing. Thus, fastener elements orientated in various directions with respect to a fastener product base can advantageously be produced.  
         [0097]     The following are incorporated by reference herein in their entirety: U.S. Pat. No. 4,794,028 issued to Fisher; U.S. Pat. No. 5,971,738 issued to Jens et al.; and U.S. Pat. No. 6,202,260 issued to Clune et al.  
         [0098]     A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention.