Patent Publication Number: US-2005136214-A1

Title: Mounting board

Description:
BACKGROUND AND FIELD OF THE INVENTION  
      The invention is an organizing surface that can be used in a vertical position. More specifically, the invention is a vertically mounted surface that allows multiple items to be secured to a variety of points on the surface.  
      It is common to use cork boards or adhesive covered boards for holding in place a variety of small objects of limited weight in a vertical position (e.g. mounted on a wall), in either an office or in a home setting. In particular, cork boards and adhesive covered boards are useful for holding very lightweight objects such as papers and photos. Adhesive covered boards are limited in the weight of the object which can be held in place due to the required repositionability or “release” of the adhesive used on the board. In the case of cork boards, typically a pin or “tack” is used to secure the object or item to the board by pushing the tack through the item and into a cork substrate mounted on a wall. Using this configuration, the object (such as a photograph) typically is damaged, since a hole is formed by the tack as it is pushed through the object in order to secure the object to the board. Additionally, the tack can only hold objects of a certain weight on the board, since at a certain low weight, the cork in the board compresses, allowing the tack to slide out and the object to fall.  
      Felt boards typically employ a hook and loop fastening system, where multiple “fishhook” shaped filaments project from a board mounted to the wall, and a mating “loop” of filament is integral to or secured to the item. When the fishhook filament and the loop filament are engaged, the object is suspended in place. This type of securing system is limited in the size of object that can be secured, since at a certain weight, the fishhook filament can bend and disengage from the object before the object falls off of the board. The level of weight that can be supported by the felt board is limited by the number of hooks and loops which can be engaged, due to the surface area of the board as well as the surface area of the object. Additionally, since the density of the fishhook filament on the board must be high to provide adequate adhesion, it is not feasible to print graphics or images behind the fishhook filaments, since the fishhook filaments obscure the viewing of any such graphics or images to a large degree.  
      Peg boards are stiff substrates, such as particle or fiber board which have holes passing through them in a spaced and consistent pattern. “Racks” or other inserts are secured to the board by positioning a portion of the rack through the spaced holes in such that the portion extending through the board has a bend extending upwardly or downwardly on the back side of the board, securing the rack in place. The portion of the rack not extended through the holes can then be used to suspend items in place. The configuration of how and where the object is held is limited due to the placement of the peg holes as well as the configuration of the rack. Additionally, the rack must be able to extend behind the board, requiring a space between any surface the peg board is mounted to in order to mount the rack or hooks in place.  
      Mushroom shaped hook fastening systems have been found to have desirable optical clarity and holding strength characteristics. Mushroom shaped fastening systems have not previously been used over a large surface area to provide a large mounting surface for many items.  
      There exists a need for a wall board that can hold a variety of objects in any configuration such as framed pictures, car keys, cell phones, office products, tools, etc. and that can additionally be aesthetically attractive for the home and office environment.  
     SUMMARY OF THE INVENTION  
      The invention is a mounting board which comprises a mounting surface. The mounting surface includes a polymeric backing and a plurality of mushroom shaped hooks extending from a first side of the backing. The mounting surface is configured to provide a mounting area large enough to allow the securing of multiple items. The mounting surface has an opacity of less than 50 percent. A stiff substrate is secured to a second side of the backing.  
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      The present invention is further described in reference to the accompanying drawings where like reference numerals refer to like parts.  
       FIG. 1  is a front view of one embodiment of the inventive mounting board.  
       FIG. 2  is an isometric view of a portion of one embodiment of the mounting surface of the inventive mounting board.  
       FIG. 3  is a partial cross-sectional view of one embodiment of the inventive mounting board as taken along line  3 - 3  of  FIG. 1 .  
       FIG. 4A  is a front view of one embodiment of a first exemplary item that may be mounted to the inventive mounting board.  
       FIG. 4B  is a front view of one embodiment of a second exemplary item that may be mounted to the inventive mounting board.  
       FIG. 4C  is a side view of a test plate configuration used in the cleavage test.  
       FIG. 4D  is a side view of a test plate configuration used in the cleavage test.  
       FIG. 5  is a schematic view of a first method for forming an extruded hook and backing used to form the mounting surface of the inventive mounting board.  
       FIG. 5A  is a cross-sectional schematic view of one embodiment of a hook from the inventive mounting board.  
       FIG. 6  is a schematic view of a further method used in forming an extruded hook and backing used to form the mounting surface of the inventive mounting board. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
      An embodiment of the current inventive mounting board is shown generally at  10  in  FIG. 1  (i.e. as a bulletin board). Mounting board  10  includes mounting surface  12  and frame  14 . Frame  14  is illustrated as completely surrounding mounting surface  12 , but could alternately extend along a portion of periphery  16  of mounting surface  12 , or be omitted from mounting board  10  entirely. Display graphics  18  may also be included as part of mounting board  10 . In one preferred embodiment of the invention, display graphics  18  are disposed behind mounting surface  12 , although display graphics  18  may alternately be printed directly on mounting surface  12 . Mounting surface  12  is large enough to provide enough area to allow multiple items  22  to be secured to mounting board  10 . In one embodiment, mounting surface  12  covers an area of at least about 4 in 2  (26 cm 2 ), preferably covers an area of at least about 80 in 2  (516 cm 2 ), and more preferably covers an area of at least 864 in 2  (5574 cm 2 ).  
       FIG. 2  illustrates a partial view of mounting surface  12 . Mounting surface  12  includes a plurality of mushroom shaped projections (or “hooks”)  20  and a substantially continuous backing  21 . Hooks  20 , extend generally perpendicularly from backing  21 . In one embodiment, hooks  20  are disposed in a generally regular array. Backing surface  21 A extends between individual hooks  20  and is preferably smooth. In one preferred embodiment, backing  21  and hooks  20  are formed from a substantially transparent film resin. In one embodiment, mounting surface  12  has an overall opacity of less than about 50 percent, preferably less than about 30 percent, and more preferably less than about 15 percent. Measurements for opacity may be conducted using standard measurement techniques, as known in the art. For example, measurements may be made on a PERKINELMER LAMBDA 900 Spectrophotometer (available from PerkinElmer, Inc., Wellesley, Mass. fitted with a PELA-100 integrating sphere accessory (available from PerkinElmer). The sphere complies with ASTM methods E903, D1003, E308, et al. as published in “ASTM Standards on Color and Appearance Measurement”, Third Edition, ATM, 1991. Measurements can be performed in general accord with ASTM Practice E1164. Opacity data can be measured using standard near-normal reflectance geometry in a six inch (150 mm) diameter integrating sphere consistent with ASTM D1003. The calculation of Opacity can be expressed as C 100 =100*R 0 /R 100 . Total Luminance Reflectance measurements can be performed by taking samples backed by a &gt;99 percent reflective white plate to obtain R 100  and again measured with a &lt;0.05 percent light trap to obtain R 0 . The calculation of C 100  parallels the calculation of C 0.89  as described in ASTM D589-97.  
      In one preferred embodiment, mounting surface  12  has an average line resolution (or average line intensity) at the 20%-80% intensity of a distance of about 0.668 mm or less when taken at a Normal viewing angle using Normal illumination. In an additional preferred embodiment, mounting surface  12  has an average line resolution at the 20%-80% intensity of a distance of about 0.631 mm when taken at a 30 degree viewing angle using 45 degree illumination. Line intensity may be tested using standard methods known in the art, for example as detailed in “Timothy Corle, Gordon Kino,  Confocal Scanning Optical Microscopy and Related Imaging Systems , Academic Press, 1996.” 
      Items  22  (see  FIG. 1 ) are secured to mounting surface  12  through an interlocking of hooks  20  with a compatible material that is either secured to or is integral with each item  22 . The mushroom-type hooks of the current invention are preferably designed so that opposing hooks can engage. This type of hook is sometimes referred to as “hermaphroditic” because the hooks have both male and female characteristics when intermeshed. One exemplary hook system which may be used in the current invention is disclosed in U.S. Pat. No. 6,076,238 incorporated by reference in its entirety herein.  
      Hooks  20  are typically of uniform height, although hooks  20  may vary in height, and may also be any desired height, cross section, or head shape. Exemplary heights of the hooks, measured from backing surface  21 A to the bottom of head  26  of hook  20 , are in the range of about 0.002 in to about 0.500 in. (about 0.005 cm to about 1.27 cm). Preferred heights of the hooks, measured from backing surface  21 A to the bottom of head  26  are in the range of about 0.025 in. to about 0.075 in. (about 0.064 cm to about 0.191 cm).  
      Exemplary heights of heads portion  26  of hooks  20 , measured from the bottom of head  26  to the top of head  26 , are in the range of about 0.002 to about 0.215 in. (about 0.005 to about 0.546 cm). Preferred heights of heads  26  of the hooks  20 , measured from the bottom of head  26  to the top of head  26 , are in the range of about 0.010 in. to about 0.030 in. (about 0.025 cm to about 0.076 cm). Alternatively, as mentioned previously, the heights of the hooks  20  may vary on the mounting surface  12 .  
      Exemplary diameters of stem portion  24  of hoods  20  are in the range of 0.003 in. to 0.070 in. (about 0.008 cm to about 0.178 cm.) Most preferred diameters of the stems are in the range of 0.008 in. to 0.016 in. (about 0.020 cm to about 0.041 cm). Stems 24 may be cylindrical or tapered. Preferred diameters of heads  26  at their outermost periphery are in the range of about 0.005 in. to about 0.150 in. (about 0.013 cm to about 0.381 cm.). More preferred diameters of heads  26  at their outermost periphery are in the range of about 0.018 in. to about 0.030 in. (about 0.046 cm to about 0.076 cm.).  
      The head density of mounting surface  12  is equal to the planar area occupied by heads  26  divided by the total area of the top surface of backing  21 . The head density may be selected based on the desired use. Preferably, the head density is selected such that engagement between a pair of opposing hooks  20  can engage, yet there is a sufficient density so that strong engagement is achieved. The head density for mounting surface  12  is preferably in the range of about 14 percent to about 45 percent. More preferably, the head density is in the range of about 30 percent to about 35 percent.  
      The number of hooks  20  in a given area may be any number, selected based on the size of the hooks  20  and head portions  26  engaging stems. One preferred density of engaging hooks is in the range of about 7 hooks/in 2  to about 22959 hooks/in 2  (1 hooks/cm 2  to 3560 hooks/cm 2 ). A more preferred density of hooks is in the range of about 285 hooks/in 2  to about 804 hooks/in 2  (44 hooks/cm 2  to 125 hooks/cm 2 ).  
      The preferred distribution of the hooks would include a plurality of engaging stems located in unordered arrangements, which repeat on a substrate. A preferred embodiment of mounting surface  12  provides a plurality of repeating unordered arrangements of the mushroom shaped hooks, where the arrangements repeat in more than one direction. The unordered arrangements of the engaging hooks allow pairs of opposing hooks to engage. Additionally, the unordered arrangements of hooks allow opposing hooks to engage with a relatively constant engagement force, and a relatively constant disengagement. force.  
      The stiffness of the hooks is related to the diameter, height, and material of the hook. For hook stem portion  24  diameters in the range of about 0.012 in to about 0.016 in. (about 0.030cm to about 0.041 cm) and stem  24  heights in the range of about 0.015 in to 0.051 in. (0.038 cm to 0.0130 cm.), the flexural Modulus is preferably in the range of about 25,000 psi to about 2,000,000 psi (172,250 kPa to 13,780,00 kPa). For stem  24  diameter of about 0.014 in (about 0.0356 cm) and a stem  24  height of about 0.037 in. (about 0.094 cm.) a more preferred flexural Modulus is approximately 200,000 psi (1,378,000 kPa).  
       FIG. 3  illustrates a partial cross-sectional view of the inventive mounting board  10  as taken along line  3 - 3  of  FIG. 1 . In the illustrated embodiment, mounting board  10  includes substrate  30  upon which display graphics  18  are printed (e.g. a poster). Substrate  30  is adhered with adhesive  32  to bottom face  21 B of backing  21 . Any number of other alternatives for creating display graphics  18  below mounting surface is contemplated by the current invention. For example, display graphics  18  can be printed directly on bottom face  21 B of backing  21 . Other bonding techniques could also be used to join display graphics  18  to backing  21 . Printing on bottom face  21 B of backing  21  could be enhanced by coating or co-extruding an ink receptive layer onto the backing  21 , or by treating bottom face  21 B of the backing  21  by corona, flame or other standard treatments or techniques.  
      A stiff base  34  may also be included as part of inventive mounting board  10 . Base  34  can be formed of any number of materials which act to stiffen the overall mounting board  10 , such as wood, plastic metal and sheetrock, among others. As illustrated, base  34  can be secured to substrate  30  using a layer of adhesive  34 , however, any number of methods known in the art to secure the base  34  in place is contemplated (e.g. mechanical fasteners). It should be understood that while the illustrated embodiment includes display graphics  18  as part of the inventive mounting board  10 , alternatively, no graphics may be incorporated. Additionally, other layers may also be included as part of the inventive mounting board  10  (not illustrated). For example, adhesive and ink primer coatings may be included in the inventive mounting board  10 .  
      Items  22  (illustrated in  FIG. 1 ) can be provided with a portion of material on its surface that is engageable with mounting surface  12 . A mating patch  40  maybe integral to each item (e.g. cloth) or may be a separate piece of material secured to the surface of the item. This “separate” mating patch  40  can be laminated by standard adhesive, heat or mechanical methods (sewing or needling) to item  22 . Examples of engageable items are illustrated in  FIGS. 4A and 4B .  FIG. 4A  illustrates a keychain  22 A including mating patch  40  of hooks  42  (similar or identical to those on mounting surface  12 ) extending from a continuous mating backing  44  that is secured to keychain  22 A.  FIG. 4B  illustrates a pen  22 B incorporated a patch  40  of loop material  46  (e.g. woven or knitted) secured to pen  22 B. Many types of mating material are contemplated which can be mated to mounting surface. This material may be secured to or integral with items  22  such as standard fibrous loop type material including non-woven material, woven or knitted loop (as illustrated), any of which may or may not be provided with a continuous backing.  
      In one embodiment, the distribution and hook configuration of the mounting surface provides for Dynamic shear force, 90° Peel Force and Engagement/Disengagement Force values as shown in Table 1.  
                           TABLE 1                                   Mounting surface               mated to same hook   Mounting surface           configuration   mated to loop           mating patch   material patch.                                                Average Dynamic Shear   at least about 40   at least about 135       Force   lb f /in 2  (275 kN/m 2 )   lb f /in 2  (931 kN/m 2 )       Average 90° Peel Force   at least about 1.7   at least about 3.1           lb/in width (0.3   lb/in width (0.55           kg/cm width)   kg/cm width)       Average Engagement   about 30 lb f /in 2     about 1.0 lb f /in 2         Force   or less (186 kN/m 2 )   or less (6.9 kN/m 2 )       Average Disengagement   about 40 lb f /in 2     about 20 lb f /in 2         Force   or less (276 kN/m 2 )   or less (138 kN/m 2 )       Average Cleavage   at least about 4.0   at least about 6.1       Strength   lb/in width (0.7   lb/in width (1.1           kg/cm width)   kg/cm width)                  
 
      Samples of hooks substantially identical mounting surface and samples of loop material (such as, for example, the loop portion of the SCOTCHMATE® brand SJ3571 hook and loop fastener, available from 3M Company, St. Paul, Minn.) attached to the mounting surface (such as, for example, 3M Brand™ DUAL LOCK™ Low Profile Fastener No. SJ4580, available from 3M Company, St. Paul, Minn.) may be tested for a dynamic shear force value, 90° peel force value, engagement force value and disengagement force value in accordance with the test method described below.  
      Dynamic Shear Testing of Mating Patch to Mounting Surface  
      The dynamic shear test measures the amount of force it takes to remove a mating patch, measuring 1 inch×1 inch (2.54 cm×2.54 cm), that is attached to a piece of mounting surface, measuring 1 inch×1 inch (2.54 cm×2.54 cm), when they are separated by pulling them in directions 180 degrees from each other. The bottom (non-mating) side of a 1 inch×1 inch (2.54 cm×2.54 cm) sample of mounting surface is secured to a 2 inch×3 inch (5.08 cm×7.62 cm) anodized aluminum test panel. The mounting surface sample is disposed about 0.5 inch (1.27 cm) from one longitudinal end of the test panel, and 0.5 inch (1.27 cm) from each transverse side of the test panel, so as to “center” the mounting surface sample at 1 inch (2.54) from one end of the test panel. A mating patch of 1 inch×1 inch (2.54 cm×2.54 cm) is secured to a 2 inch×3 inch (5.08 cm×7.62 cm) anodized aluminum test panel. The mating patch sample is disposed about 0.5 inch (1.27 cm) from one longitudinal end of the test panel, and 0.5 inch (1.27 cm) from each transverse side of the test panel, so as to “center” the mating patch sample at 1 inch (2.54) from one end of the test panel. The one test panel and mating patch is placed on top of the other test panel and mounting surface sample (face to face) to achieve a 1 inch×1 inch engagement area, with the longitudinal ends of each test panel not containing the mounting surface and mating patch disposed at 180 degrees from each other (i.e. not “mirrored) . The engaged specimen is pressed together using finger pressure, then the plate with the mating patch is twisted approximately 20 degrees in each direction to more fully engage. The mated mounting surface and mating patch sample are placed on a flat surface. An 8 pound (3.6 kg) steel bar is placed over the engaged portion of the sample and roll a 4-½ pound (2 kg) roller over a 2 inch (5.08 cm) span over the sample for 6 passes (3 cycles) using at a rate of approximately 12 inches (30.5 cm) per minute.  
      The aluminum test plate having the affixed mating patch is secured into upper jaw of a tensile tester, (such as an INSTRON™ Model 1122, manufactured by Instron Corporation, Canton, Mass.). The metal plate having the affixed mounting surface is placed into the lower jaw and clamped securely such that the tensile tester pulls the mounting patch in a direction 180 degrees from the direction the mounting surface is pulled. The shear force is recorded at a tensile tester crosshead speed of 12 inches (30.5 cm) per minute.  
      90 Degree Peel of Testing of Mating Patch to Mounting Surface  
      The peel test measures the amount of force it takes to remove a mating patch measuring 1 inch (2.54 cm)×1 inch (2.54 cm) that is attached to a piece of mounting surface while peeling the mating patch from the mounting surface at a 90 degree angle and constant peel rate. A 1 inch×1 inch (2.54 cm×2.54 cm) sample of mating patch material is placed on a mounting surface sample. The overlapped specimen is rolled by hand, once in each direction, using a 4.5 pound (100 gram) roller at a rate of approximately 12 inches (30.5 cm) per minute, to engage the mounting surface sample and the mating patch.  
      The mating patch was then place into the lower jaw of a tensile tester (such as an INSTRON™ Model 1122, manufactured by Instron Corporation, Canton, Mass.). Without pre-peeling the sample, the leading edge is placed in to the upper jaw of the tensile tester. The tensile tester is then engaged. The peel force of removing the mating patch from the piece of mounting surface is recorded, while being maintained at a 90 degree angle, at a crosshead speed of 12 inches (30.5 cm) per minute.  
      Engagement and Disengagement Test  
      This test determines the force needed in pounds for the disengagement and engagement of a mating patch measuring 1 inch (2.54 cm)×1 inch (2.54 cm) that is attached to a piece of mounting surface while peeling the mating patch from the mounting surface at a 90 degree angle and constant peel rate. A 1+/−{fraction (1/64)} inch×1+/−{fraction (1/64)} inch (25.4+/−0.4 mm×25.4+/−0.4 mm) sample of mating patch material is placed on a mounting surface sample 1+/−{fraction (1/64)} inch×1+/−{fraction (1/64)} inch (25.4+/−0.4 mm×25.4+/−0.4 mm). Each sample is mounted to the center of a separate test block. One test block is mounted to a stationary jig (such as a Chatillon model LTS Test Stand or equivalent, Chatillon Company, Greensboro, N.C.) and one test block is mounted to a digital force gauge (such as a Chatillon Model DFG digital force gauge, Chatillon Company, Greensboro, N.C.). The mating patch and the mounting surface sample are aligned to face each other (face to face) and the clamps of the digital force gauge (moving jig) and the test stand (stationary jig) are centered. The Digital Force Gauge is set to “lb.”, “Norm”, and compression mode, and zeroed. The specimens are engaged at about 8 inches+/−1 inch per. minute (305 mm+/−51 mm per minute). When the mating patch consists of hooks substantially identical to the hooks of the mounting surface, the force required to engage the specimens will suddenly decrease when engagement is achieved and an audible click may be heard. The engagement force is recorded. The Digital Force Gauge is then set into the tension mode and zeroed. The specimens are disengaged at about 8 inches+/−1 inch per minute (305 mm+/−51 mm per minute). The disengagement force is recorded.  
      Cleavage Test  
      This test determines determines the cleavage strength of a mating patch measuring 1 inch±{fraction (1/16)} (25.4 mm±1.6 mm)×2.25 inch±{fraction (1/16)} (57.2 mm±1.6 mm) to a dynamic cleavage force that is attached to a piece of mounting surface measuring 1 inch±{fraction (1/16)} (25.4 mm±1.6 mm)×2.25 inch±{fraction (1/16)} (57.2 mm±1.6 mm). Two clean, bare aluminum plates are required. For clarification purposes,  FIGS. 4C and 4D  are provided to illustrate the configuration of the aluminum test plates. Both plates shall be 2″ (illustrated by reference letter M)×3″ and have a single ¼″ diameter hole (illustrated by reference letter N) centered along the 2″ width of the plate and located ⅜″ from centerline (illustrated by reference letter O) to the plate&#39;s edge and a 45 degree bend (illustrated by reference letter P) located {fraction (9/16)}″ from the end of the plate (illustrated by reference letter Q).  
      The mating patch is adhered to one aluminum test plat and the mounting surface sample is adhered to the other aluminum test plate. Both the mating patch and surface sample should be oriented with the end even with the unbent edge of the respective test plate and centered on the 2″ width of the test plate, extending forward towards the bent portion (illustrated by reference letter R). Each plate should be place in a mirrored overlapping configuration such that the mounting surface sample is overlapped with the mating patch and such that the angled portion of the plates are disposed at the same end forming the test specimen. The mating patch and mounting surface sample are engaged by carefully aligning them on top of one another and using increasing finger pressure to press the mating patch against the mounting surface sample. When the mating patch consists of hooks substantially identical to the hooks of the mounting surface, an audible click may be heard. A hook is slid through the hole in one of the test plates and the hook clamped in the lower, fixed jaw of a tensile tester (such as an INSTRON™ Model 1122, manufactured by Instron Corporation, Canton, Mass.). Enough clearance should be provided so that the test plate can freely rotate about the hookias the,test is being conducted. Holding the test specimen approximately horizontal and perpendicular to the clamping plane of the jaws, another hook is looped through the hole in the remaining upper plate. The second hook is clamped in the movable jaw of the tensile tester. Enough pre-tension should be provided to the specimen to maintain it in a roughly horizontal position when external support is removed. The tensile tester is engaged at a crosshead speed of 12 inches (30.5 cm) per minute. The cleavage strength is the maximum dynamic force applied to the sample when removing the mating patch from the piece of mounting surface is recorded.  
      Method for Forming Mounting Surface  
      A first exemplary method of forming mounting surface  12  for use in inventive mounting board  10  is by extruding a thermoplastic resin through a die onto a continuously moving mold surface with cavities. One exemplary process is illustrated in  FIG. 5 . A feed stream of preselected thermoplastic resin is fed by conventional means into extruder  106  which melts the resin and moves the heated resin to die  108 . Die  108  extrudes the resin as a wide ribbon of material onto a mold surface  110 , e.g., a cylinder, having an array of mold cavities  112  in the form of elongated shaped holes. The mold cavities can be connected to a vacuum system (not shown) to facilitate resin flow into the mold cavities. This could require a doctor blade or knife to remove excess material extruded into the interior face of the mold cylinder. Mold cavities  112  preferably terminate in the mold surface having an open end for entry of the liquid resin and a closed end. In this case, a vacuum could be used to at least partially evacuate mold cavities  112  prior to entering die  108 . Mold surface  110  preferably matches that of die  108  where they are in contact to prevent excess resin being extruded out, e.g., the die side edges. The mold surface and cavities can be air or water cooled, or the like, prior to stripping the integrally formed backing  21  and upstanding projection elements  128  (e.g. hooks) from the mold surface such as by a stripper roll  118 . This provides a continuous web of mounting surface  12 . Alternatively, upstanding projection elements  128  could be formed on a preformed backing or the like by extrusion molding or other known techniques.  
      In the embodiment illustrated, the nip is formed by extruder die  108  and roll  110  but alternatively the polymer could be extruded between two roll surfaces or the like. The nip or gap is sufficient that backing  21  is also formed over the cavities. Backing  21  preferably has a smooth surface along bottom face  21 B back but could have a textured or rough surface. The formed mounting surface  12  material has projection elements  128  projecting from backing  21  which mounting surface  12  material is removed from the mold surface by a take-up device  118 . A vacuum can be used to evacuate the cavities for easier extrusion into the cavities.  
      Cavities  112  could be in the shape of final mushroom shaped hooks  20  as disclosed, for example, in U.S. Pat. No. 6,174,476. In this embodiment, cavities  112  are in the shape of final hook  20 , and a generally continuously tapered hook shaped projection element  128  is pulled from continuously tapered hook cavities, directly resulting in hooks  20 . Alternatively, the extruded mounting surface  12  could also provide a web of material provided with projection elements  128  only partially formed into hooks, or as shown in  FIG. 6 , as unformed projection elements  128 . Tip portion  126  of these projection elements  128  (or the tips of partially formed hooks) then need to be subsequently formed into finished hooks  20 . Forming the hooks may be accomplished by deforming tip portions  126  under heat and pressure. The heat and pressure could be applied sequentially or simultaneously. In one method, heat and pressure are selectively applied to tip portion (or distal end)  126  in nip  121 . In this case, nip  121  is provided which has at least one first heated surface member  122  and at least one second opposing surface member  124 . The final mounting surface  12  has formed hook heads  20  formed from projection elements  128 . The heated calender roll  122  contacts a predetermined portion of tip portion  126  of projection elements  128  projecting upward from backing  21 . The roll temperature will be that which will readily deform tip portion  126  under pressure created by the nips in compression zone  138  without causing resin to stick to roll  122  surface. Roll  122  surface can be treated with release coatings resistant to high temperature to allow for higher temperatures and/or longer contact times between the tip portion  126  and the heated roll  122 .  
      One embodiment of an exemplary hook  20  is illustrated in  FIG. 5A . The hook  20  comprises a thin strong flexible film-like backing  21  having generally parallel backing surface (upper face)  21 A and bottom face  21 B, hook  20  projects from upper face  21 A of backing  21 . Backing  21  can have planar surfaces or surface features as could be desired for tear resistance or reinforcement. Hook  20  comprises stem portion  24  attached at one end to backing  21  and preferably has tapered sections  76  that widen toward the backing  21  to increase the hook anchorage and breaking strengths at their junctures with backing  21 , and head portion  26  at the end of stem portion  24  opposite backing  21 . Sides  34  of head portion.  26  can be flush with sides  35  of stem portion  24  on two opposite sides. Head portion  26  has hook engaging parts or arms  36 ,  37  projecting past stem portion  24  on one or both sides. Hook  20  preferably has a rounded surface  78  opposite stem portion  24  to help head portion  26  enter between loops if fastened to a loop style mating patch  40 . Head portion  26  also has transverse cylindrically concave surface portions  79  at the junctures between stem portion  24  and the surfaces of head portion  26  projecting over backing  21 .  
      Backing  21  is preferably thick enough to allow it to be attached to a substrate by a desired means such as sonic welding, heat bonding, sewing or adhesives, including pressure sensitive or hot melt adhesives, and to firmly anchor hooks  20 .  
      Suitable thermoplastic materials for forming mounting surface  12 , however formed, include generally transparent polyolefins such as polypropylenes or polyethylenes, polyamides such as nylon, polyesters such as poly(ethylene terephthalate), plasticized polyvinyl chloride, copolymers and blends thereof, optionally, with other polymers or plasticizers, or the like or coextruded versions.  
      Other methods for forming mushroom shaped hooks which are known in the art may also be used without departing from the spirit and scope of the invention. For example, the method for forming mushroom shaped hooks shown and described in U.S. Pat. No. 4,290,174, which is incorporated by reference in its entirety herein.